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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,
Onan P218 Air-Cooled,
Cycle 120/240 V AC, 60 Hz
Tw Two- o-Cylinder Cylinder, Four , Four- -C Cy
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TABLE OF CONTENTS SECTION 1 – SAFETY PRECAUTIONS FOR SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1-2. Servicing Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1-3. EMF Information . . . . . . . . . . . . . . . . . . . . . .
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SECTION 7 – DISASSEMBLY AND REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 7-1. Disassembly Of Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 7-2. Disassembly Of Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 SECTION 8 – MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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SECTION 1 – SAFETY PRECAUTIONS FOR SERVICING safety_rtm1 4/95 1-1. Symbol Usage Marks a special safety message. Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols. Means NOTE; not safety related. This group of symbols means Warning! Watch Out! possible ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult symbols and related instructions below for necessary actions to avoid the hazards. 1-2. Servicing Hazar
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HOT PARTS can cause severe burns. HIGH-FREQUENCY RADIATION can 1. Allow cooling period before servicing. interfere with radio navigation, safety 2. Wear protective gloves and clothing when working services, computers, and on a hot engine. communications equipment. 1. Have only qualified persons familiar with ELECTRIC SHOCK HAZARD from electronic equipment perform this installation. incorrect use of test equipment. 2. The user is responsible for having a qualified 1. Stop engine before making or
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SECTION 2 – INSTALLATION 2-1. Installing Welding Generator Movement Airflow Location 18 in Do Not Lift Unit From End (460 mm) 18 in (460 mm) 18 in (460 mm) OR OR 18 in 18 in (460 mm) (460 mm) Grounding 1 Generator Base 3 2 Metal Vehicle Frame 1 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- tected extension cord. Electrically bond generator frame to vehicle frame by metal-to-metal
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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
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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 Miller Legend TM-428 Page 5
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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)
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SECTION 3 – OPERATING WELDING GENERATOR 3-1. Front Panel Controls 5 6 1 2 7 3 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 For best arc starts, use lowest amper- and s
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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
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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 Miller Legend TM-428 Page 9
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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. 1115 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 overload. If CB3 opens, receptacle 2 does not work. 1 Ref. ST-168 046 4-2. AC Auxiliary Power Curve SB-115 571 TM-428 Page 10 Miller Legend
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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 3 12 5 6 78 9 Ref. ST-168 046 If unit does not have GFCI recep- tacle Reset button pops out and the circuit 8 Circuit Breaker CB2 tacles, use GFCI-protected exten- opens to disconnect the faulty equipment. CB1 and CB2 protect all the 60 Hz recep- Check for damaged tools, cords, plugs, etc. sion cord. tac
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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 Remote Control weld. The speed and excitation cur- Switch S4 rent of the field coils determine volt- ages in stator windings. Remote 14 Panel 3 Stator Windings ♦ ♦ 12 12 Supply power to exciter, auxiliary power, and weld circuits. Capacitor Board Remote PC5 And Remote 14 Control Board 4 Fuse F1 Receptacle RC1 PC3 Prot
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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 equipmen
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NOTES TM-428 Page 14 Miller Legend
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SECTION 6 – TROUBLESHOOTING 6-1. Troubleshooting Tables A. Welding See Sections 6-2 and 6-3 for test points and values and Section 10 for parts location. Trouble Remedy No weld output. Check fuse F1, and replace if necessary (see Section 8-6). Check integrated rectifier SR2, and replace if necessary. Check diode D4, and replace if necessary. Clean slip rings, and install new brushes if necessary (see Section 6-15). Disconnect leads 21, 23, and 33 from brushes, and check continuity across slip
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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. Clean slip rings, and install new brushes if necessary (see Section 6-15). Check
