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February 1996Form: TM-428Effective With Serial No. JH242114TECHNICAL MANUALService And PartsMiller Legend(Formerly The Legend AEAD-200LE)CC AC/DC Welding Generator For SMAW, GMAW, GTAW WeldingWeldingWeldRatedMaximumAuxiliary PowerOutputWeldingOpen-CircuFuel CapacityEngineModeRatingRangeOutputit Voltage225 A, 25 V,Single-Phase,CC/AC35 ± 225 A100% Duty805 kVA/kW, 42/21 A,Onan P218 Air-Cooled,Cycle120/240 V AC, 60 HzAnd7.5 gal (28 L) TankT wo-Cylinder, Four-Cycle,200 A, 25 V,Single-Phase,Gasoline EngineCC/DC25 ± 200 A100% Duty721 kVA/kW, 9 A,Cycle115 V AC, 100 Hzcovertm 4/95 ± ST-140 091-E1996MILLER Electric Mfg. Co.PRINTED IN USA. SECTION 7 ± DISASSEMBLY AND REASSEMBLY.337-1.Disassembly Of Unit.337-2.Disassembly Of Generator.34SECTION 8 ± MAINTENANCE.358-1.Routine Maintenance.358-2.Maintenance Label.368-3.Servicing Air Cleaner.378-4.

Changing Engine Oil, Oil Filter, And Fuel Filter.388-5.Adjusting Engine Speed.398-6.Overload Protection.408-7. Inspecting And Cleaning Optional Spark Arrestor.40SECTION 9 ± ELECTRICAL DIAGRAMS.41SECTION 10 ± PARTS LIST.51. This group of symbols means Warning! Possible ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult symbols and related instructions below for necessary actions to avoid the hazards. Servicing HazardsWARNINGThe symbols shown below are used throughout this manual to call attention to and identify possible hazards. When you see the symbol, watch out, and follow the related instructions to avoid the hazard.Only qualified persons should service, test, maintain, and repair this unit.During servicing, keep everybody, especially children, away.

ELECTRIC SHOCK can kill.1. Do not touch live electrical parts.2. Stop engine before testing or repairing unit unless the procedure specifically requires an energized unit.3.

Insulate yourself from ground by standing or working on dry insulating mats big enough to prevent contact with the ground.4. Do not leave live unit unattended.5. When testing live unit, use the one-hand method.Do not put both hand inside unit. Keep one hand free.MOVING PARTS can cause injury.1. Keep away from moving parts such as fans, belts, and rotors.2. Have only qualified people remove guards or covers for maintenance and troubleshooting as necessary.3.

Keep hands, hair, loose clothing, and tools away from moving parts.4. Before working on generator, remove spark plugs or injectors to keep engine from kicking back or starting.5. Block flywheel so that it will not turn while working on generator components.6. Reinstall panels or guards and close doors when servicing is finished and before starting engine.FLYING PIECES OF METAL or DIRT can cause injury.1.

Always wear safety glasses with side shields or face shield during servicing.2. Be careful not to short metal tools, parts, or wires together during testing and servicing.STATIC ELECTRICITY can damage parts on circuit boards.1.

Put on grounded wrist strap BEFORE handling boards or parts.2. Use proper static-proof bags to store, move, or ship PC boards.ENGINE EXHAUST GASES can kill.1. Do not breathe exhaust fumes.2.

Use in open, well-ventilated areas, or vent exhaust outside and away from any building air intakes. ENGINE FUEL can cause fire or explosion.1. Stop engine before fueling.2. Do not fuel while smoking or near sparks or flames.3. Do not overfill tank; clean up any spilled fuel.BATTERY EXPLOSION can BLIND and INJURE.1.

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

Flush eyes and skin immediately with water.STEAM AND PRESSURIZED HOT COOLANT can burn face, eyes, and skin.1. Check coolant level when engine is cold to avoid scalding.2.

If the engine is warm and checking is needed, follow steps 3 and 4.3. Wear safety glasses and gloves and put a rag over cap.4. Turn cap slightly and let pressure escape slowly before completely removing cap.FALLING EQUIPMENT can cause serious personal injury and equipment damage.1. Use equipment of adequate capacity to lift components.2. Use a lifting eye to lift unit only, NOT running gear, gas cylinders, or any other accessories.3. Securely attach components to lifting equipment. Selecting Weld Cable SizesTotal Cable (Copper) Length In Weld Circuit Not Exceeding100 ft (30 m) Or Less150 ft200 ft250 ft300 ft350 ft400 ft(45 m)(60 m)(70 m)(90 m)(105 m)(120 m)Welding10 ± 60%60 ± 100%10 ± 100% Duty CycleAmperesDuty CycleDuty Cycle/11/02/3211/02/03/211/02/03/04/02-2/02-2/030011/02/03/04/02-2/02-3/02-3/03501/02/03/04/02-2/02-3/02-3/02-4/0Weld 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-D2-8.

Remote 14 Receptacle RC1 InformationSocket.Socket InformationAContact closure to B completes 15 volts dc contactor controlcircuit.B15 volts dc.C+4.5 volts dc output to remote control.AKJADRemote control circuit common.BIC LNHE0 to +4.5 volts dc input command signal from remote control.DMGEFKChassis common.ST-140 092-B.The remaining sockets are not used. Y If unit does not have GFCI receptacles, use GFCI-protected extension cord.1 120 V 15 A AC Duplex Receptacle RC12 120 V 15 A AC Duplex Receptacle RC23 240 V 30 A Twistlock Receptacle RC3Receptacles supply 60 Hz single-phase power at power/idle speed only. Maximum output from each duplex receptacle is is 2.5 kVA/kW. Maximum output from twistlock receptacle is 5 kVA/kW. For 60 Hz auxiliary power, set controls as shown in table.4 120 V 15 A AC Duplex GFCI Receptacles GFCI1 And GFCI2 (Optional)If a ground fault is detected, the GFCI recep. Tacle Reset button pops out and the circuit opens to disconnect the faulty equipment. Check for damaged tools, cords, plugs, etc.

Connected to the receptacle. Press button to reset receptacle and resume operation. At least once a month, run engine at power/idle speed and press Test button to verify GFCI is working properly.5 Circuit Breaker CB56 Circuit Breaker CB7CB5 protects RC1 and CB7 protects RC2 from overload. If CB5 or CB7 opens, the receptacle does not work. Press button to reset breaker.7 Circuit Breaker CB1.

8 Circuit Breaker CB2CB1 and CB2 protect all the 60 Hz receptacles from overload. If CB1 or CB2 opens, the 240 volt receptacle and one of the 120 volt receptacles does not work. 120 volts may still be present at the 240 volt receptacle. Press button to reset breaker.9 Total Auxiliary Power OutputCombined output of receptacles limited to the 5 kVA/kW output of the generator:EXAMPLE: If 10 A is drawn from a 120 V duplex receptacle, only 16 A is available at the 240 V receptacle:(120 V x 10 A) + (240 V x 16 A) = 5.0 kVA/kW. 1 EngineSupplies force to turn revolving fields.2 Revolving Fields (Rotor)Turn at 1860 rpm maximum for power/idle and 3000 rpm maximum for weld. The speed and excitation current of the field coils determine voltages in stator windings.3 Stator WindingsSupply power to exciter, auxiliary power, and weld circuits.4 Fuse F1Protects exciter excitation winding from overload.5 Integrated Rectifier SR2Changes ac output of stator windings to dc to supply excitation current to the exciter revolving field.6 Control Relay CR5Energizes when voltage is present in exciter stator to disconnect field flashing circuit.7 Idle Module PC1 And Idle LockSwitch S1PC1 and S1 control engine speed. 13 ♦Remote ControlSwitch S4Remote 14Panel12 ♦12 ♦Capacitor BoardRemotePC5 And Remote 14Control BoardReceptacle RC1PC311VoltageRegulatorBoard PC218FineCR3AmperageControl R1312Voltage60 Hz AuxiliaryRegulatorPowerEngineRevolvingStator WindingsFields (Rotor)100 HzExciterWeldAuxiliary5Power84IntegratedThrottleFuseSolenoidRectifier SR2F1TS16 ♦9ControlCurrentRelayTransformerCR5CT17716Idle ModuleIdle LockCircuitPC1Switch S1BreakerCB31017Control Relays100 HzCR2, CR3, CR4Auxiliary PowerReceptacle RC4.

TroubleRemedyNo 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 rotorif 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%. ReplaceR1 if necessary (see Section 3-1).Disconnect leads 22 and 29 from SCR/integrated rectifier SR2, and check for continuity between leads22 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, andreplace if necessary.Check reactor AC-Z for signs of winding failure. Check continuity across windings, and check for properconnections. Replace AC-Z if necessary.Check resistance and connections of Fine Amperage control R1; R1 is 0 to 30 ohms ± 10%. ReplaceR1 if necessary.Disconnect leads 21, 23, and 33 from brushes, and check continuity across slip rings. Replace rotorif 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 forproper 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 Section6-16).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 properconnections. Replace AC-Z if necessary. 50 Or 60 Hz Auxiliary PowerTroubleRemedyNo 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 breakersCB5 and CB7 (see Section 4-3).Check receptacles RC1, RC2, RC3 for continuity and proper connections.

Replace receptacle(s) if nec-essary.Check connections to terminal strip 1T.Clean slip rings, and install new brushes if necessary (see Section 6-15).Check coil voltage and connections of control relay CR4. Check continuity of coil and condition of con-tacts. Replace CR4 if necessary.Check diode D4, and replace if necessary.Check idle board/module PC1 and connections (see Section 6-5).Check control transformer T1 for signs of winding failure.

Check continuity across windings, and checkfor proper connections. Check primary and secondary voltages. Replace T1 if necessary.Disconnect leads 21, 23, and 33 from brushes, and check continuity across slip rings. Replace rotorif necessary.Disconnect leads 48 and 49 from voltage regulator board PC2, and check continuity between leads 48and 49. Disconnect leads 50, 51, 52, and 53 from stator. Check continuity between leads 50 and 51,and 52 and 53. Replace stator if necessary.Low auxiliary power output.Check connections to terminal strip 1T.Clean slip rings, and install new brushes if necessary (see Section 6-15).Check integrated rectifier SR2, and replace if necessary.Check coil voltage and connections of control relay CR3.

Check continuity of coil and condition of con-tacts. Replace CR3 if necessary.Check voltage regulator board PC2 and connections, and replace if necessary.High auxiliary power output.Check engine speed, and adjust if necessary.Check voltage regulator board PC2 and connections, and replace if necessary (see Section 6-9).C. 100 Hz Auxiliary PowerTroubleRemedyNo auxiliary power output at receptacleRun 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 and93.

Replace stator if necessary.Check diode D4, and replace if necessary. EngineTroubleRemedyEngine 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 manualgine Control switch S2 returns to Runfor location). S3 should close when engine is running.position.Check and refill crankcase with proper viscosity oil for operating temperature, if necessary (see enginemanual).Check continuity of Engine Control switch S2, and replace if necessary.Engine stopped during normal opera-Check oil level (see Section 2-4). Check low oil pressure shutdown switch S3 (see engine parts manualtion.for location). S3 should close when engine is running.Check continuity of Engine Control switch S2, and replace if necessary.Battery discharges between uses.Make sure Engine Control switch S2 is placed in the Off position when engine is not in use (see Section3-1).Prior to Serial No.

Engine does not go to weld rpm with Engine Control switch S2 in Run position.Connect meter (DC) between terminals D (+) and E (±).Start engine. Place EngineControl switch S2 in Run position.Prior to Serial No. JH300534, move Weld/Power switch S1 to Weld position.Check connectionsNO to Engine Control+12 volts dc present?switch S2 andground connection(lead 33).YESConnect meter (DC) between terminals C (+) and E (±).NO Replace idle+12 volts dc present?board/modulePC1YESCheck circuit breaker CB4, throttle solenoid TS1 connections and linkage, and control relay CR2.Reinstall cover. Control Relays CR3 and CR4 do not energize at idle rpm (See Section 5 for CR3 and CR4 information)Connect meter (DC) between terminal A (+) and F (±) prior to Serial No. JH300534, or B (+) and F (±) effective with Serial No.

JH300534.Start engine. Place EngineControl switch in Run position.NO Replace idle0 (zero) volts dc present?

Board/module PC1YESPlace Engine Control switch S2 in Run/Idle position.NO Replace idle+12 volts dc present? Board/module PC1YESCheck control relaysCR3 andCR4.Reinstall cover. Voltage Regulator Board PC2 Testing Information Prior To Serial No. KE604176Be sure plugs are secure before21testing. See Section 6-8 for specif-ic values during testing.1Voltage Regulator Board PC22Terminals A Thru GTest Equipment Needed:Ref.

ST-800 698-A / SA-099 497-B6-8. Voltage Regulator Board PC2 Test Point Values Prior To Serial No.

KE604176a) Tolerance ± ±10% unlessPC2 Voltage Readingsspecifiedb) Reference ± to circuit com-mon (lead 33) unless notedReceptacleValueA Circuit commonB 18 volts ac input with respect to pin AC 18 volts ac input with respect to pin AD Circuit commonE 130 volts ac input with respect to terminal G at power/idle rpmF 55 volts dc output with respect to terminal D at power/idle rpmG 130 volts ac input with respect to terminal E at power/idle rpmTM-428 Page 26Miller Legend. Voltage Regulator Board PC2 Testing Information Effective With Serial No.KE60417612Be sure plugs are secure beforetesting. See Section 6-10 for spe-cific values during testing.1Voltage Regulator Board PC22Receptacle RC1Test Equipment Needed:Ref. ST-800 698-A / SA-160 889-A 6-10. Voltage Regulator Board PC2 Test Point Values Effective With Serial No. KE604176a) Tolerance ± ±10% unlessPC2 Voltage Readingsspecifiedb) Reference ± to circuit com-mon (lead 33) unless notedReceptaclePinValueRC1118 volts ac input with respect to pin 52Not used318 volts ac input with respect to pin 54Circuit common5Circuit common6130 volts ac input with respect to pin 8 at power/idle rpm7Not used8130 volts ac input with respect to pin 6 at power/idle rpm955 volts dc output with respect to pin 4 at power/idle rpmMiller LegendTM-428 Page 27.

Test Equipment Needed:Ref. ST-800 698-A / ST-115 941-L / SA-138 2476-12. ST-800 698-A / SA-156 026-C 6-14. Optional Remote Capacitor Board PC5 Test Point Values Effective With Serial No.

Replacing Brushes And Cleaning Slip RingsA. Checking Brushes And Cleaning Slip RingsStop engine and allow to cool.1 Brush Holder Retaining Bar2Brush Holder BracketRemove brush holder bracket.Keep hardware for reinstallation.3Brush Holder4Brush With Spring5Brush Holder CapMark and disconnect leads atcaps, and remove brushes frombracket.Replace brushes if damaged, or ifbrush is at or near minimum length.6Slip RingsInspect slip rings. Under normaluse, rings turn dark brown.If slip rings are corroded or surfaceis uneven, insulate brush leads,start engine, and clean rings with acommutator stone. Remove aslittle material as possible.

Stop en-gine.Install brushes, bracket, and re-maining generator parts. Adjustbrushes as shown in Section B.Reinstall both side panels and topcover.253415/16 in. (8 mm)Minimum Length9/16 in. (14.3 mm)New LengthReplaceDamaged BrushesTools Needed:1/2 inST-800 698-A / Ref. ST-115 942-F / S-0233-ATM-428 Page 30Miller Legend.

B.Adjusting Brush PositionStop engine.Afterinstallingbrushes,adjustbrush position as follows:1Brush Holder2Brass Sleeve3Brush4Slip RingLoosenbrushholderbracketmounting hardware. Move bracketuntil brass sleeves are positionedas shown. Tighten hardware.Reinstall side panels and cover.If operation is still not okay, have aqualified machine shop turn andpolish slip rings.Side View3/32 in(2.4 mm)3214Correct Brush PositionIncorrect Brush PositionTop ViewCenter brushes on sliprings.43 21CorrectIncorrectBrush PositionBrush PositionTools Needed:3/8, 1/2 inRef.

ST-800 698-A / Ref. ST-800 677-B. Check engine speeds, and adjust if necessary (see Section 8-5).1 115 VAC 100 Hz Receptacle RC4With no load applied and engine running at weld rpm, there should be 128 to 132 volts ac present at RC4.2 Slider3 Resistor R4Y Stop engine before adjusting R4If 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 TerminalsTurn Fine Amperage control R1 to max. With no load applied and engine running at weld rpm, there should be 70 to 72 volts dc present at dc weld terminals.5 Resistor R2Y Stop engine before adjusting R2If correct voltage is not present, adjust slider on R2 until correct voltage is obtained at dc weld terminals. Do not exceed 72 volts dc.Stop engine. Allow engine to cool, and then complete pre-operational checks in table.Reinstall cover and side panels.Ref.

ST-800 698-A / ST-800 249. 8 HoursWipe UpCheck FluidLevels.SpillsOILSee Section 2-4Full20 HoursCheck AndClean SparkArrestor Screen25 HoursClean AndCheck AirCleaner50 HoursClean AndTighten WeldTerminals100 HoursChange Oil. SeeChange Oil Filter. SeeSection 8-4 AndSection 8-4 AndMaintenanceMaintenance LabelLabelClean CoolingClean AndSystem,TightenSee EngineBatteryManualConnections200 HoursCheckReplaceReplaceFuel Filter.ValveUnreadableSee SectionClearanceLabels8-4.500 HoursRepair Or ReplaceCheckSparkCracked CablesPlugs1000 HoursORBlow Out Or Vacuum Inside.During Heavy Service,Clean Monthly. ONAN P218 GAS ENGINESee Engine Manual for complete engine care. Give engine Specification and Serial Number when ordering parts.To Drain Oil:° C° F+30+100CheckPush AndTurn CCW+2030daily.1/2 in. ID Hose+10+40Pull010WRecommended Oil.

API Service Classification-10SF, SG, SF/CC, SG/CE-20030Oil & Filter Change.-305W-dirty conditions. 25 hours or lessnormal conditions.

100 hoursOil Filter. MILLER 065 251, Onan 122-0645Oil Capacity.1.5 qt (1.4 L) or 1.75 qt (1.6 L) with filter changeFuel Grade.

Regular or UnleadedFuel Filter. MILLER 066 113, Onan 149-2206-01,Fram G10E1GasolineAir Filter Service. 100 hours or less ± see Owner's ManualAir Filter Element. MILLER 064 617, Onan 140-2522Air Filter Wrapper. MILLER 065 653, Onan 140-149612 Volt Battery. BCI Group 58+430 Amps min.Cranking Performance at 0 °F (-18 °C).Engine RPM ± No LoadValve Clearance ± ColdPower.1650 (50 Hz)In0.005 in (0.13 mm)1860 (60 Hz)Ex0.013 in (0.33 mm)Weld3000Spark Plug Gap.0.025 in. (0.6 mm)Spark Plug.Champion RS17YX Preferred orRS14YCUse only resistor spark plugs and wires.Spark Arrestor Inspection And Service.20 operating hours -see Owner's ManualOptionalS-176 891. Save game digimon world data squad.

Changing Engine Oil, Oil Filter, And Fuel FilterStop engine and allow to cool.1Oil Drain Valve2 1/2 ID x 12 in Hose3Oil FilterChange engine oil and filter ac-cording to engine owner's manual.Y Close valve and valve capbefore adding oil and run-ning engine.Fill crankcase with new oil to fullmark on dipstick (see Section 8-2).Full4Fuel Filter5Fuel LineReplace line if cracked or worn.Install new filter. Wipe up anyspilled fuel.Start engine, and check for fuelleaks.Stop engine, tighten connectionsas necessary, and wipe up fuel.45321Tools Needed:ST-140 091-E / ST-144 840-C Ref.

ST-168 046 / ST-800 395 / S-0842TM-428 Page 38Miller Legend. After tuning engine, check engine speeds with a tachometer. See table for proper no load speeds. If necessary, adjust speeds as follows:Start engine, and place Engine Control switch in Run/Idle position. Turn Fine Amperage control to 100.1 Carburetor2 Throttle SolenoidPower/Idle Speed Adjustment3 Power/Idle Speed Rod4 Lock Nut5 Adjustment NutLoosen lock nut and rotate adjustment nut until engine runs at power/idle speed.

Tighten lock nut.Weld Speed AdjustmentPlace Engine Control switch in Run position.6 Lock Nut Loosen nut.7 Hex SwivelTurn swivel until engine runs at weld speed. Tighten lock nut.8 Weld Speed Governor Spring9 Power/Idle Speed Governor SpringIf a spring becomes loose or disconnected, reattach as shown. 8-6.Overload ProtectionStop engine.1 Circuit Breaker CB4 (Internal± Not Shown)CB4 protects the unit from over-load due to an obstructed throttlesolenoid.

If CB4 opens, enginespeed drops to power/idle rpm forabout 10 seconds before automati-cally resetting.If CB4 continues to open, checkthrottle solenoid TS1 and throttlelinkage.2 Fuse F1 (See Parts List ForRating)F1 protects the exciter excitationwinding from overload.2Replace open fuse and reinstallpanel before operating unit.If F1 continues to open, check inte-grated rectifier SR2 and rotor.Tools Needed:3/8 inST-152 264-A8-7. Inspecting And Cleaning Optional Spark ArrestorStop engine and allow to cool.1 Spark Arrestor ScreenClean and inspect screen. Replace spark arrestor if screen wires are broken or missing.1Tools Needed:1/4 inST-140 091-E / ST-801 206 / Ref. 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. ItemDia.PartDescriptionQuantityNo.Mkgs.No.Figure 10-1. Main Assembly.1.042 132.REMOTE CONTROL, (Figure 10-6) (Prior to JK713332).

1.1.042 383.REMOTE CONTROL, (Figure 10-6) (Eff w/JK713332). 1.2.Figure 10-5.CONTROL PANEL, w/components. 113 302.UPRIGHT, base (Prior to KA780148). 129 384.UPRIGHT, base (Eff w/KA780148 thru KA892304).

136 057.UPRIGHT, base (Eff w/KA892305 and on). 107 342.SEAL, lift eye. 113 303.PANEL, side. +113 304.COVER, top (Prior to JJ365634). +114 557.COVER, top (Eff w/JJ365634 thru KF812088).

1.6.+173 209.COVER, top (Eff w/KF812089). 120 304.BLANK, snap-in nyl.250mtg hole (Eff w/JJ365634 thru KB133271). 143 397.BLANK, snap-in nyl.312mtg hole (Eff w/KB133272 thru KF812088). 108 487.LABEL, warning falling equipment etc. 113 439.PANEL, rear lower (Prior to KA780148).

128 789.PANEL, rear lower (Eff w/KA780148 thru KA892304). 136 059.PANEL, rear lower (Eff w/KA892305 and on). 095 970.STRIP, nprn wsl eng firewall 18 in. 088 731.BUSHING, snap-in nyl.375 ID. 11.PLG5.HOUSING, (part of engine wiring harness).

113 248.TANK, fuel (Prior to KA780148) (consisting of). CAP, tank fuel. NECK, tank fuel. TUBE, pick up fuel.

010 863.CLAMP, hose 2 1/16-3 clamp dia (Prior to KA780148). 107 346.HOSE, fuel tank (Prior to KA780148). 107 324.BRACKET, support pipe filler (Prior to KA780148).

107 343.GROMMET, rubber neck filler fuel (Prior to KA780148). 113 486.COVER, fuel tank (Prior to KA780148). 113 392.HOLD DOWN, fuel tank (Prior to KA780148). 113 294.SUPPORT, center mtg engine (Prior to KA780148). 147 601.CAP, tank screw-on w/vent. 130 123.TANK, fuel 7.5gal (Eff w/KA780148 thru KG037343). 177 606.TANK, fuel 7.5gal (Eff w/KG037344 and on).

145 976.HOSE, nprn SAE.250 ID. 084 173.CLAMP, hose.460±.545clp dia. 066 113.FILTER, fuel inline.250 (included w/engine). 17.CLAMP, hose.460±.545clp dia (included w/engine). 18.HOSE, nprn SAE.250 ID (included w/engine) (order by ft). 135 627.ENGINE, gas elect start (Prior to KG037344) (consisting of).

178 479.ENGINE, gas elect start (Eff w/KG037344) (consisting of). FITTING, pipe brs cap.375NPT (Prior to KF933389). FITTING, pipe galv nipple L.375NPT (Prior to KF933389). VALVE, oil drain (Eff w/KF933389). MUFFLER, exhaust engine (Prior to KF926822). MUFFLER, exhaust (Eff w/KF926822).

SOLENOID, 12VDC 20A. BRACKET, mtg solenoid (Prior to JK595850). BRACKET, mtg solenoid(Eff w/JK595850). LINKAGE KIT, (Prior to JJ404117). SWIVEL, in-line.250-28 (Eff w/JJ404117). LINK, throttle (Eff w/JJ404117). SPRING, high speed.

137 046.TUNE-UP & FILTER KIT, (consisting of). ELEMENT, air cleaner. OIL FILTER. FILTER/CLAMPS, fuel. SPARK PLUG. ItemDia.PartDescriptionQuantityNo.Mkgs.No.Figure 10-1. Main Assembly (Continued).

107 308.HOLD DOWN, bat (Prior to KB113874). 146 697.HOLD DOWN, bat (Eff w/KB113874 thru KF959176). 165 631.HOLD DOWN, bat (Eff w/KF959177 and on). 010 493.BUSHING, snap-in nyl.625 ID x.875mtg hole (Prior to KA780148). 165 630.BOLT, J stl.250±20 x 6.125 (Eff w/KF959177). 168 385.LABEL, warning battery explosion.

115 511.BRACKET, support cover (Prior to KF812089). 107 270.DOOR, access battery (Prior to KF959177). 175 887.DOOR, access battery (Eff w/KF959177).

088 577.CABLE, bat pos (Prior to KF959177) (consisting of). 167 731.CABLE, bat pos (Eff w/KF959177) (included w/engine) (consisting of). COVER, cable bat post red. 071 678.BATTERY, stor 12V (Prior to KF959177). 168 037.BATTERY, stor 12V (Eff w/KF959177). 114 923.BOOT, insulator term post red (Prior to KA780148). 135 571.BOOT, insulator term post red ( Eff w/KA780148 thru KC220663).

108 081.TERMINAL PROTECTOR, battery post mtg. 020 279.CLAMP, stl cushion.750 dia x.281mtg hole (Eff w/KA780148). 107 753.CABLE, bat neg (Prior to KA780148) (consisting of). 023 641.CABLE, bat neg (Eff w/KA780148 thru KE668694) (consisting of).

167 730.CABLE, bat neg (Eff w/KE668695) (consisting of). COVER, cable bat post blk. 34.Figure 10-2.GENERATOR. 113 298.BASE, (Prior to KA780148). 132 195.BASE, (Eff w/KA780148 thru KB113873).

146 710.BASE, (Eff w/KB113874 and on). 134 792.LABEL, warning general precautionary engine etc. 057 360.BLANK, snap-in nyl 1.375mtg hole.

113 450.STABILIZER. 113 451.REACTOR. 142 503.RECTIFIER, si 1ph 300A.

113 562.BRACKET, mtg resistor (Prior to JK559100). 126 072.BRACKET, mtg-resistor (Eff w/JK559100).

114 544.PANEL, front lower. 43.Figure 10-3.PANEL, front w/components. 105 370.TRANSFORMER, current.

012 571.HOLDER, fuse mintr.083 596.FUSE, mintr cer 12A 250V. 008 951.RESISTOR, WW adj 180W 12 ohm. 046 819.SUPPRESSOR. 116 045.HOUSING PLUG & PINS, (consisting of).

CONNECTOR, rect univ 084 pin 20-14ga. 109 994.LABEL, warning engine fuel can cause fire. 013 367.LABEL, warning moving parts can cause serious injury. 135 475.KIT, label (Prior to KF959177). 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 PartsBE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.

ItemDia.PartDescriptionQuantityNo.Mkgs.No.Figure 10-2. Generator (Figure 10-1 Item 34).1.

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). 10.049 286. ROTOR ASSEMBLY, gen (consisting of). 11.017 624.

FAN, rotor gen. 12.053 390. BEARING, ball rdl sgl row 1.37. 13.024 617. RING, retaining ext 1.272 shaft. 1.602 348. KEY, stl.250 x.250 x.750.

14.SR2.035 704. RECTIFIER, integ 40A 800V. 15.007 250. BRACKET, mtg brushholder. 16.047 878. BAR, retaining brushholder.

17.161 306. CAP, brushholder. 18.126 984.

BRUSH w/SPRING. 19.005 614. HOLDER, brush.

ST-115 942-FFigure 10-2. Generator+When ordering a component originally displaying a precautionary label, the label should also be ordered.Recommended Spare Parts.BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS. ItemDia.PartDescriptionQuantityNo.Mkgs.No.Figure 10-3. Panel, Front w/Components (Figure 10-1 Item 43).1. 604 176.RECEPTACLE, str dx grd 2P3W 15A 125V (Prior to KE629034).

073 690.PLUG, str grd armd 2P3W 15A 125V P&S 5266 DF. 167 657.RECEPTACLE, str dx grd 2P3W 15A 125V (Eff w/KE629034).

115 427.CIRCUIT BREAKER, man reset 1P 25A 250VAC (Prior to KE629034). 168 057.CIRCUIT BREAKER, man reset 1P 20A 250VAC (Eff w/KE629034). 113 315.PANEL, front (Prior to JK713332).

130 352.PANEL, front (Eff w/JK713332 thru KB133271). 143 383.PANEL, front (Eff w/KB133272 thru KF790319).

170 554.PANEL, front (Eff w/KF790320 and on). 005 563.SWITCH, selector (Figure 10-4). 081 712.RHEOSTAT, WW 100W 30 ohm. 011 609.SWITCH, tgl SPDT 15A 125VAC (Prior to JK713332). 011 611.SWITCH, tgl DPDT 15A 125V (Eff w/JK713332).

035 523.CONNECTOR, circ MS/MET 5skt sz 16S rect MS-3102A-16S-8SAmphenol (Prior to JK713332). 1Figure 10-41922ST-115 943-JFigure 10-3. Panel, Front w/Components.

ItemDia.PartDescriptionQuantityNo.Mkgs.No.Figure 10-3. Panel, Front w/Components (Figure 10-1 Item 43)(Continued).

039 273.CONNECTOR, circ MS/MET 5 pin sz 16S MS-3106A-16S-8P Amphenol. 039 685.CONNECTOR, circ MS/MET clamp str rlf sz 16-16S AN-3057-8 Amphenol.7. 086 022.CONNECTOR, circ MS/MET 14skt sz 20 MS-3102A-20-27S(Eff w/JK713332 thru KD344393). 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 20-22SAmphenol AN-3057-12.7. 156 025.CIRCUIT CARD, connector/receptacle (Eff w/KD344394).

097 749.CAPACITOR, (Eff w/JK713332 thru KD344393). 011 622.SWITCH, tgl 3PDT 15A 125VAC (Prior to JK713332). 011 611.SWITCH, tgl DPDT 15A 125V (Eff w/JK713332). 172 070.SWITCH, ignition. 083 432.CIRCUIT BREAKER, man reset 1P 10A 250V.

601 836.NUT, brs hex jam hvy.250-20. 010 915.WASHER, flat brs.250 ID x.625 OD. 083 030.STUD, brs grd.250-20 x 1.750. ♦ 042 130.METER KIT, (Prior to KD548030) (consisting of). METER, hour.

145 247.METER, hour 12-24VDC (Eff w/KD548030). 144 474.CIRCUIT BREAKER, man reset 1P 25A 250VAC (Eff w/KE629034). 604 103.RECEPTACLE, str dx grd 2P3W 15A 250V (Prior to JH300534). 025 234.PLUG, str grd 2P3W 15A 250V Leviton 5443. 129 067.RECEPTACLE, twlk grd 3P4W 30A 125/250V (Eff w/JH300534).

088 898.PLUG, twlk grd 3P4W 30A 125/250V. 034 952.RECEPTACLE, str 3P3W 15A 125V. 073 690.PLUG, str grd armd 2P3W 15A 125V P&S 5266 DF. 18.NAMEPLATE, (order by model & serial number).

039 047.TERMINAL, pwr output red (consisting of). 039 046.TERMINAL, pwr output black (consisting of). 099 255.TERMINAL, pwr output neutral (consisting of). SCREW, cap stl hex hd.500-13 x 1.500. TERMINAL BOARD, red. TERMINAL BOARD, black.

TERMINAL BOARD, neutral. NUT, stl hex jam.500-13.

BUS BAR, term bd. NUT, stl hex full fnsh.500-13. 073 756.STAND-OFF, No. 6-32 x.625 lg x.250 hex (Eff w/KD344394). 153 501.HOUSING PLUG & SOCKETS, (Eff w/KD344394) (consisting of). CONNECTOR, rect univ 039skt 22-18.

115 109.CAPACITOR, (Prior to KD344394). 148 021.CIRCUIT CARD, filter HF (Eff w/KD344394). 111 584.CONTROL, push-pull (Prior to JH283238). 116 813.CONTROL, push-pull (Eff w/JH283238).

119 014.LEVER, switch. 108 864.CAP, dust connector 9760-16 (Prior to JK713332). 109 993.CAP, dust connector 9760-20 (Eff w/JK713332). 097 924.KNOB, pointer. 010 647.PIN, spring cs.156 x 1.250. 021 385.BOOT, tgl switch lever.

115 493.HANDLE, switch range. 1Part of Remote Control Option♦ Effective w/KD548030 Optional Meter Kit became Standard Equipment.BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS. ItemPartDescriptionQuantityNo.No.005 563Figure 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. 10.052 405.

SPRING, pressure contact switch. 11.052 404. CONTACT, movable switch. 12.005 557.

BUS BAR, switch range. 13.005 558. SPRING, selector switch.

41232113ST-097 264-AFigure 10-4. Switch, SelectorBE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS. ItemDia.PartDescriptionQuantityNo.Mkgs.No.Figure 10-5. Control Panel, w/Components (Figure 10-1 Item 2).1. 038 601.BLOCK, term 30A 9P (Prior to JK713332). 130 648.BLOCK, term 30A 10P (Eff w/JK713332). 113 682.BRACKET, mtg components (Prior to JK713332).

130 649.BRACKET, mtg components (Eff w/JK713332). 083 147.GROMMET, scr No.8/10. 049 404.CIRCUIT CARD, regulator 115V (Prior to KE604176). 160 888.CIRCUIT CARD, voltage regulator (Eff w/KE604176) (Figure 10-7).

168 071.CONNECTOR & SOCKETS, (Eff w/KE604176) (consisting of). CONNECTOR, rect skt 20-14ga. 113 247.RELAY, encl 12VDC DPDT. 044 588.RELAY, encl 12VDC 3PDT.

173 069.RELAY, encl 12VDC SPDT. 045 061.CIRCUIT BREAKER, auto reset 24VDC 7A. 113 492.CIRCUIT CARD, weld/idle (Prior to JH300534). 142 725.MODULE, pull to weld/power delay (Eff w/JH300534). 059 389.DIODE, rect 3A 1000V SP (Prior to JH300534).

059 389.DIODE, rect 3A 1000V SP (Eff w/JH300534). 116 083.TRANSFORMER, control (Prior to KE604176). 167 404.TRANSFORMER, control (Eff w/KE604176). 038 620.LINK, jumper term blk 30A. 117 566.DIODE, rect 6A 600V. 1123Figure 075968 ST-114 309-BFigure 10-5. Control Panel, w/ComponentsBE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.

ItemDia.PartDescriptionQuantityNo.Mkgs.No.+042 132Figure 10-6. Remote Control, Option (Figure 10-1 Item 1)+042 383.1.

136 246.CIRCUIT CARD ASSEMBLY, remote control. 110 375.STAND-OFF SUPPORT, PC card.

116 086.BRACKET, mtg remote control (Prior to JK563388). 125 873.BRACKET, mtg remote control (Eff w/JK563388). 052 603.RELAY, encl 110VDC DPDT.

007 532.CLAMP, capacitor 1.000dia. 059 887.CAPACITOR, polyp met film 10uf 220V. 116 005.BLOCK, term 10A 7P. 108 023.LINK, jumper term blk 10A. 115 091.HOUSING PLUG & SOCKETS, (consisting of).

TERMINAL, female 1skt 18-24W. 5SB-116 028Figure 10-6. Remote Control, Option+See Figure 10-3 for additional parts not listedBE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS. Dia.PartDescriptionQuantityMkgs.No.PC2160 888Figure 10-7. Circuit Card, Voltage Regulator (Figure 10-5 Item 4). A50.165 411. IC, linear 2904.

C1.003 530. CAPACITOR, cer mono 1uf 50VDC. C50.119 199.

CAPACITOR, polye met film 1uf 50V. C51.053 992. CAPACITOR, cer disc.001uf 1000VDC. C52.000 348.

CAPACITOR, tantlm.47uf 35V. C53.005 023. CAPACITOR, tantlm 2.2uf 20V. C54.072 935.

CAPACITOR, elctlt 33uf 35VDC. C55.137 463. CAPACITOR, polye met film.22uf 100VDC.

C56.072 113. CAPACITOR, tantlm 4.7uf 35VDC. C57.028 292. CAPACITOR, cer disc.005uf 1000VDC. D50.028 351.

DIODE, sig 200mA 75V SP. D51.049 641. DIODE, zener 27V 1W. D52-54.026 202. DIODE, rect 1A 400V SP. D55-58.070 250. DIODE, rect 3A 600V.

D59.030 529. DIODE, rect 22A 600V RP. Q50.039 355.

TRANSISTOR, ujt 15mA 40V. Q51,52.037 200. TRANSISTOR, NPN 200mA 40V. Q53,54.049 642.

THYRISTOR, SCR 8A 600V. R50.094 447. RESISTOR, MF.25W 681K ohm.

R51.044 789. RESISTOR, MF.25W 100K ohm. R52.035 829. RESISTOR, MF.25W 1.5K ohm. R53,54,65.072 559.

RESISTOR, MF.25W 22.1K ohm. R55.115 530. RESISTOR, MF.25W 2.67K ohm. R56,64.000 885. RESISTOR, MF.25W 10K ohm. R57,62.028 285.

RESISTOR, C.5W 100 ohm. R58,63.035 823. RESISTOR, MF.25W 100 ohm.

R59.072 559. RESISTOR, MF.25W 22.1K ohm. R60.074 026. RESISTOR, C.25W 150 ohm.

R61.138 301. POTENTIOMETER, cermet trmr 1/T.5W 25K ohm. R66.093 030. RESISTOR, MF.25W 15K ohm. R67.093 032. RESISTOR, MF.25W 26.7K ohm. R68.108 437.

RESISTOR, MF.25W 4.75K ohm. R69.049 439. RESISTOR, C 2W 47K ohm. R70.074 099. RESISTOR, C 1W 150 ohm.

R71.030 707. RESISTOR, C 1W 47 ohm. RC1.160 892. CONNECTOR, rect 9 pin 3 row rcpt.

VR50.083 772. IC, rgltr 7815.

1SA-160 889Figure 10-7. Circuit Card, Voltage Regulator PC2BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.