Miller Electric Legend AEAD-200LE Technical Manual Download Page 58

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TM-428 Page 54

Miller Legend

Description

Quantity

Part

No.

Dia.

Mkgs.

Item

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)

. . .

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

. . .

. .

071 970

COVER, cable bat post red

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

. . . . .

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

BAT

071 678

BATTERY, stor 12V (Prior to KF959177)

. . .

. . . .

. . .

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

BAT

168 037

BATTERY, stor 12V (Eff w/KF959177)

. . .

. . . .

. . .

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

114 923

BOOT, insulator term post red (Prior to KA780148)

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

. . .

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

135 571

BOOT, insulator term post red ( Eff w/KA780148 thru KC220663)

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

. . .

. . . . . .

108 081

TERMINAL PROTECTOR, battery post mtg

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

. . .

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

020 279

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

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

. . .

. . . . . . . . .

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)

. . .

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

. . .

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

071 971

COVER, cable bat post blk

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

. . . . .

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

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

. . .

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

. . .

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

DC-Z

113 450

STABILIZER

. . .

. . . .

. . .

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

AC-Z

113 451

REACTOR

. . .

. . . .

. . .

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

SR1

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

. . .

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

. . .

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

Figure 10-3

PANEL, front w/components

. . .

. . . . . . . . . . .

. . .

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

CT1

105 370

TRANSFORMER, current

. . .

. . . .

. . .

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

012 571

HOLDER, fuse mintr

. . .

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

. . .

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

*083 596

FUSE, mintr cer 12A 250V

. . .

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

. . .

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

R2,4

008 951

RESISTOR, WW adj 180W 12 ohm

. . .

. . . .

. . .

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

R3,VR1

046 819

SUPPRESSOR

. . .

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

RC5

116 045

HOUSING PLUG & PINS, (consisting of)

. . .

. . . .

. . .

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

113 633

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)

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

. . .

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

+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.

Summary of Contents for Legend AEAD-200LE

Page 1: ...W GTAW Welding Welding Mode Weld Output Range Rated Welding Output Maximum Open Circu it Voltage Auxiliary Power Rating Fuel Capacity Engine CC AC 35 225 A 225 A 25 V 100 Duty Cycle 80 Single Phase 5...

Page 2: ...ary 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...

Page 3: ...ENANCE 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 4...

Page 4: ......

Page 5: ...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 EXHA...

Page 6: ...g Booklet Part No 150 853 when servicing this unit 2 Consult the Owner s Manual for welding safety precautions 3 Use only genuine MILLER replacement parts 4 Reinstall injectors and bleed air from fuel...

Page 7: ...have GFCI receptacles use GFCI pro tected extension cord 2 OR 18 in 460 mm 18 in 460 mm 18 in 460 mm 18 in 460 mm 18 in 460 mm OR Movement Airflow Location Grounding OR Y Do Not Lift Unit From End 2 2...

Page 8: ...gend 2 3 Fuel Consumption SB 115 572 2 4 Engine Prestart Checks ST 140 091 E Ref ST 151 983 Check all fluids daily Engine must be cold and on a level surface Engine stops if oil pressure gets too low...

Page 9: ...1 2 in Y Connect cable last Ref ST 144 839 F Ref ST 168 046 Ref S 0756 D 2 6 Connecting To Weld Output Terminals Y Use ONLY one set of termi nals at a time Disconnect weld cables from set of weld outp...

Page 10: ...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 amp...

Page 11: ...l switch to Start position Release switch and slowly push choke in when en gine starts Do not crank engine while fly wheel is turning To Stop turn Engine Control switch to Off position 4 Remote Contro...

Page 12: ...l to RC1 see Section 2 8 ST 140 092 B 1 Min 70 A DC Max 88 A DC Adjust Remote Control Set Range Set Percentage Min 70 A DC Percentage Of Range 50 Max 88 A DC 50 of 70 to 105 In Example Set Switch 3 3...

Page 13: ...nd 3 4 Volt Ampere Curves SB 115 529 A SB 115 528 A The volt ampere curves show the minimum and maximum voltage and amperage output capabilities of the welding generator Curves of other settings fall...

Page 14: ...te 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 Break...

Page 15: ...le Press button to reset receptacle and resume operation At least once a month run engine at power idle speed and press Test button to verify GFCI is working properly 5 Circuit Breaker CB5 6 Circuit B...

Page 16: ...weld rpm 10 Control Relays CR2 CR3 CR4 CR2 energizes at weld rpm to supply power to throttle solenoid TS1 CR3 energizes at power idle rpm to bypass fine amperage control R1 CR4 energizes at power idle...

Page 17: ...oarse range of weld out put from weld stator 20 Reactor AC Z Tapped reactor limits weld output and provides coarse ranges 21 Main Rectifier SR1 Changes ac output from weld windings to dc 22 Stabilizer...

Page 18: ...TM 428 Page 14 Miller Legend NOTES...

Page 19: ...ld 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...

Page 20: ...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 5...

Page 21: ...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...

Page 22: ...ine 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 CR2 energized Field current at weld rpm V14 R17...

Page 23: ...s ac 5 V8 AC output to PC2 21 volts ac 5 V9 AC output from Regulator Power Winding power idle rpm 158 volts ac 5 V10 AC output from Weld Winding at weld rpm 65 volts ac R1 at min 80 volts ac R1 at max...

Page 24: ...checking resistance R1 29 ohms R2 34 ohms R3 35 ohms R4 2 ohms R5 2 ohms R6 thru R17 Less than 1 ohm CR2 energized Field current at weld rpm Throttle control relay control relay CR3 and auxiliary powe...

Page 25: ...s ac 5 V8 AC output to PC2 21 volts ac 5 V9 AC output from Regulator Power Winding power idle rpm 158 volts ac 5 V10 AC output from Weld Winding at weld rpm 65 volts ac R1 at min 80 volts ac R1 at max...

Page 26: ...0 V A DC Open Circuit Voltage Ampere Ranges Switch S5 In Max Position 2 ms 10 V B DC Weld Output 25 Volts DC 100 Am peres Ampere Range Switch S5 In 70 105 Position Resistive Load 5 ms 50 V C AC Open C...

Page 27: ...g Information Ref ST 800 698 A SC 113 702 A 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 Modu...

Page 28: ...weld load applied Engine does not go to weld rpm with load applied NO main rectifier SR1 NO 0 zero volts dc present Connect meter DC between terminal D and E YES NO Connect meter DC between terminal...

Page 29: ...D and E Prior to Serial No JH300534 move Weld Power switch S1 to Weld position Control Relays CR3 and CR4 do not energize at idle rpm See Section 5 for CR3 and CR4 information Reinstall cover NO YES...

Page 30: ...Voltage Regulator Board PC2 Test Point Values Prior To Serial No KE604176 PC2 Voltage Readings a Tolerance 10 unless specified b Reference to circuit com mon lead 33 unless noted Receptacle Value A Ci...

Page 31: ...Regulator Board PC2 Test Point Values Effective With Serial No KE604176 PC2 Voltage Readings a Tolerance 10 unless specified b Reference to circuit com mon lead 33 unless noted Receptacle Pin Value RC...

Page 32: ...lts 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 respec...

Page 33: ...ltage Readings a Tolerance 10 unless specified b Reference to circuit com mon lead 33 unless noted Receptacle Pin Value RC1 A Contact closure to pin B completes the dc contactor control circuit B 15 v...

Page 34: ...s 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...

Page 35: ...ve 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 Ref ST 8...

Page 36: ...o max With no load applied and en gine running at weld rpm there should be 70 to 72 volts dc present at dc weld terminals 5 Resistor R2 Y Stop engine before adjust ing R2 If correct voltage is not pre...

Page 37: ...ne 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 Y Do not damage rot...

Page 38: ...Brush Holder Cap 15 Brush 16 Brush Holder Reassembly Reinstall engine and generator parts as needed see torque table Reconnect fuel line choke cable and base ground cable Reinstall spark plugs battery...

Page 39: ...ark Arrestor Screen 25 Hours Clean And Check Air Cleaner 50 Hours Clean And Tighten Weld Terminals 100 Hours Change Oil See Section 8 4 And Maintenance Label Change Oil Filter See Section 8 4 And Main...

Page 40: ...lter Element MILLER 064 617 Onan 140 2522 Air Filter Wrapper MILLER 065 653 Onan 140 1496 Spark Plug Gap 0 025 in 0 6 mm Spark Plug Champion RS17YX Preferred or RS14YC Use only resistor spark plugs an...

Page 41: ...not run engine without air cleaner or with dirty ele ment Stop engine 1 Precleaner Wash precleaner with soap and water solution Allow precleaner to air dry completely Spread 1 tablespoon SAE 30 oil ev...

Page 42: ...ge engine oil and filter ac cording to engine owner s manual Y Close valve and valve cap before adding oil and run ning engine Fill crankcase with new oil to full mark on dipstick see Section 8 2 4 Fu...

Page 43: ...ck Nut 5 Adjustment Nut Loosen lock nut and rotate adjust ment nut until engine runs at pow er idle speed Tighten lock nut Weld Speed Adjustment Place Engine Control switch in Run position 6 Lock Nut...

Page 44: ...TS1 and throttle linkage 2 Fuse F1 See Parts List For Rating F1 protects the exciter excitation winding from overload Replace open fuse and reinstall panel before operating unit If F1 continues to op...

Page 45: ...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 s...

Page 46: ...TM 428 Page 42 Miller Legend SC 114 477 A Figure 9 1 Circuit Diagram For Miller Legend Without Remote Control Effective With Serial No JH242114 Thru JH300533...

Page 47: ...TM 428 Page 43 Miller Legend SC 168 053 A Figure 9 2 Circuit Diagram For Miller Legend Without Remote Control Effective With Serial No KE629034 And Following...

Page 48: ...gend Coat terminals with dielectric grade nonconductive electric grease MILLER Part No 146 557 or equivalent Figure 9 3 Wiring Diagram For Miller Legend Without Remote Control Effective With Serial No...

Page 49: ...TM 428 Page 45 Miller Legend SD 168 051 B...

Page 50: ...TM 428 Page 46 Miller Legend SC 115 947 A Figure 9 4 Circuit Diagram For Miller Legend With Remote Control Effective With Serial No JH242114 Thru JH300533...

Page 51: ...TM 428 Page 47 Miller Legend SC 168 054 A Figure 9 5 Circuit Diagram For Miller Legend With Remote Control Effective With Serial No KE629034 And Following...

Page 52: ...B 113 710 Figure 9 6 Circuit Diagram For Idle Control Board PC1 Effective With Serial No JH242114 Thru JH300533 SB 160 891 Figure 9 7 Circuit Diagram For Voltage Regulator Board PC2 Effective With Ser...

Page 53: ...TIVE SUPPLY OUTPUT Figure 9 8 Circuit Diagram For Optional Remote Control Board PC3 Effective With Serial No KA840710 And Following SB 148 024 A Figure 9 9 Circuit Diagram For HF Filter Board PC4 Effe...

Page 54: ...TM 428 Page 50 Miller Legend SB 156 027 Figure 9 10 Circuit Diagram For Optional Capacitor Board PC5 Effective With Serial No KD346698 And Following...

Page 55: ...ary 1996 Form TM 428 Effective With Serial No JH242114 SECTION 10 PARTS LIST TM 428 Page 51 Miller Legend Miller Legend Formerly The Legend AEAD 200LE CC AC DC Welding Generator For SMAW GMAW GTAW Wel...

Page 56: ...egend Figure 10 5 Figure 10 1 Main Assembly 19 20 21 22 23 24 25 26 1 2 3 4 5 6 7 8 9 10 11 27 28 31 32 35 36 38 39 40 41 42 43 45 46 47 48 49 29 37 44 51 50 12 13 30 14 15 16 17 18 33 34 Figure 10 2...

Page 57: ...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 KA7...

Page 58: ...LE 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 K...

Page 59: ...0 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...

Page 60: ...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...

Page 61: ...W 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...

Page 62: ...ACT 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 pres...

Page 63: ...66 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...

Page 64: ...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 10...

Page 65: ...5mA 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 5...

Page 66: ...Notes...

Page 67: ...Notes...

Page 68: ......

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