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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. California Proposition 65 Warnings 3......................................................

1-4. EMF Information 3.....................................................................

SECTION 2 − DEFINITIONS 4..................................................................

2-1. Additional Safety Symbols And Definitions 4................................................

2-2. Miscellaneous Symbols And Definitions 4.................................................

SECTION 3 − SPECIFICATIONS 5..............................................................

3-1. Description 5..........................................................................

3-2. 4 kW Model Specifications 5.............................................................

3-3. 7.5 kW Model Specifications 5...........................................................

3-4. AC Power Curve 6.....................................................................

SECTION 4 − MAINTENANCE AND TROUBLESHOOTING 7.......................................

4-1. Maintenance Schedule 7................................................................

4-2. Overload Protection 7..................................................................

SECTION 5 − 4 kW MODELS THEORY OF OPERATION 8.........................................

SECTION 6 − 7.5 kW MODELS THEORY OF OPERATION 9.......................................

SECTION 7 − TROUBLESHOOTING 4kW GENERATOR 10.........................................

7-1. Troubleshooting Table 10.................................................................

7-2. Field Flashing 11........................................................................

SECTION 8 − TROUBLESHOOTING 7.5kW GENERATOR 12.......................................

8-1. Troubleshooting Table 12.................................................................

8-2. Troubleshooting Circuit Diagram For Welding Generator 14....................................

8-3. Waveforms For Section 8-2 16............................................................

8-4. Power Board PC1 Testing Information 17...................................................

8-5. Power Board PC1 Test Point Values 17.....................................................

8-6. Control Board PC2 Testing Information 18...................................................

8-7. Control Board PC2 Test Point Values 18....................................................

8-8. Inspecting Brushes, Replacing Brushes, And Cleaning Slip Rings 19............................

8-9. Setting Control Board PC2 For 50 Hz Operation 20...........................................

8-10. Checking Unit Output After Servicing 21....................................................

SECTION 9 − DISASSEMBLY AND REASSEMBLY 22..............................................

9-1. Disassembling/Reassembling 4 kW Generator 22............................................

9-2. Disassembling/Reassembling 7.5 kW Generator 23...........................................

SECTION 10 − ELECTRICAL DIAGRAMS 24......................................................

SECTION 11 − 4 kW MODEL EFF w/ME131503R 34................................................

SECTION 12 − 7.5 kW MODEL EFF w/MD040275R 37..............................................

Miller TM-268 User Manual

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