Form: SPM-449FMiller February 1993Big 2OTMEffective With Serial No. HJ213165

SERVICE PARTSMANUAL

A WARNINGSERVICING can be hazardous. Have all service procedures performed only by qualified persons following standard safety practices.

Use only genuine MILLER replacement U For help, call Factory Parts Department atparts. 414-735-4500.

Use MILLER Testing Booklet (Part No or write to: MILLER ELECTRIC Mfg. Co.150 853) when servicing this unit P.O. Box 1079, Appleton, WI 54912

spin 12/92 PRINTED IN ~SA

4 0

Fig 4

Figure 1. Main Assembly

112

1

Fig 7

8!

76

3

SPM-440 Page 1 Big 20

Fig 2

TO-007 288-K

Big 20 SPM-449 Page 2

Replace Coils at Factory or Factory Authorized Service Station

Item Dia.No. Mkgs. Description

Figure 1. Main Assembly

070010089517

.3 010434.4 030194

.5 1150006 ... 602938

.7 010869

.8 010870

.9 01560210 00601411 08148912 01028913 01747914 03186815 01876516 ... 018859

008 698- . 17 021 117

18 .. *01730919 ... 00027220 ... 01836521 ... 01086122 023626

10808123 ... 022 89924 +005 612

080 90625 +081 485

10848726 ... 035 96827 02752928 049 68529 ... 053 96629 12350330 01736331 08994632 60598233 01119834 08150035 00601536 12350437 09141738 049143

13640539 oos 77240 .. ESi .. 005 37341 047 47442 01049343 oos 73943 oos 74043 071 194

01083744 049 640

.45 ...SS...SPM-449 Page 3

025 473

BOLT, J 1/4-20 x 2-5/16STRAP, fuel tankSTRIP,rbrl/2x2x4-1/2TANK, fuel (consisting of)

. . . CAP, tank-fuelFITTING, pipe-plug sq hd 1/8NPTFITTING, pipe-bushing 1/4 x 1/8NPTFITTING, pipe-brs nipple hex 1/8NPTVALVE, shutoffFITTING, brs-flared inverted elb male 1/4 x 1/8NPTLINE, fuelFITTING, brs-flared inverted connector M 1/4TBG 1/8SEAL, weather-lift eyeBRACKET, mtg-air cleanerAIR CLEANER, intake-carburetor (consisting of)

CAP, air cleanerBAFFLE, dustcapWING NUT

.... ELEMENT, air cleanerCLAMP, air cleaner

HOSE, intake-air cleanerCLAMP, hose 1-1/16 - 2 clamp dia

. CABLE, battery insulated 32 in Ig 3/8 clampTERMINAL PROTECTOR, battery postDOOR, access-batteryDOOR, sideLABEL, engine maintenance (LH door)COVERtop

- . LABEL, warning falling equipmentWASHER, neoprene 5-7/8 OD x 3-5/8 ID x 1/16PIN, cotter 1/4x3-1/2CATCH, doorGUARD, fan (Prior to JJ493072)GUARD, fan LH (Eff w/JJ493072)HOSE, radiator-upperRADIATOR, w/shroud (consisting of)

.... CAP, radiator 7 lb pressureLABEL, warning fanENCLOSURE, radiatorFITTING, pipe brs drain cock 1/4NPTGUARD, fan RH (Eff w/JJ493072)HOSE, radiatorENGINE, gas-electric (Prior to KA775726) (consisting of)ENGINE, gas electric (Eff w/KA775726) (consisting of)

... CONTROL, weld/idle (consisting of)SOLENOID, 1 2VDC 84A pull typeBRACKET, mtg-idle deviceBUSHING, snap 5/8 ID x 7/8 mtg holeSTRIP, mtg throttle (Prior to JB474519)STRIP, mtg throttle (Prior to JB474519)STRIP, mtg-throttle (Eff w/JB47451 9)PIN,spring3/32x5/8

.... LEVER, control idleSWITCH, low oil

PartNo. Quantity

.222

2121121622111121111111111111111

Big 20

Item Dia.No. Mkgs.

PartNo. Description Quantity

Figure 1. Main Assembly (Continued)

.46 .56... 02547447 081 49848 602 21649 601 87950 601 99351 ALT,REG144399

02683752 60543053 025 18154 061 4415556 088 78157 081 46758 004 719

602 887114772

.59 Fig260 00413061 01051562 017477

63 BATT ... 071 678 64 023641

023 89265 0174316667 05360668 +005 78069 +Fig770 00571071 01026672 01742073 010679

..74 08148175 +049 08275 +111 31176 006340

.77 Fig378 02765779 005601

-. 79 09355979 00639780 134792

080 030601 836

81 Fig482 .. R2 .... 03076483 . . . Zi .... 005727

005 658005 659005 660

84 02821885 081 98386 .. CT1 ... 095 04287 . . . Z2 .... 005726

..88 07138889

Big 20

SWITCH, high temperatureBRACKET, mtg-alternator 1WASHER, lock-split 1/2 1NUT, hex-full 1/2-13 1SCREW, cap-hex hd 1/2-13 x 2-1/2 1ALTERNATOR, 37A 12V w/regulator 1INSULATOR, term-nyl 1PULLEY, single belt 1TUBING, 5/8 OD x 12 ga wall x 1/2 1STRAP, adjust alternator 1

- . BELT, fan (included w/engine-see engine parts list) 1BLADE, fan 1

. PIPE, exhaust 1CAP, weather-exhaust pipe 1FITTING, pipe-brs plug hex hd 1/4NPT 1STARTER, engine 1

GENERATOR 1BRACKET, support-door 2BOLT, J 5/16-18 4ROD, holddown-battery 2BATTERY, 12V74A 1CABLE, battery neg 1CABLE, grd 1HOLDER, battery 1MOUNT, engine (included w/engine-see engine parts list) 1UPRIGHT, base-center 1PANEL, side-RH 1PANEL, open circuit 1LABEL, caution this panel must be etc 1SPRING, extension 2LATCH, door 2MOUNT, dual stud 2 x 3 in 2BASE 1UPRIGHT, base-front (Prior to JG0981 59) 1UPRIGHT, base-front (Eff w/JG0981 59) 1BAR, shield-lift support 1BRACKET, mtg-pwr output 1LABEL, grd 1PANEL, front-lower (Prior to JE739902) 1PANEL, front-lower or (Eff w/JE739902) 1PANEL, front-lower (used w/plrt switch) 1LABEL, warning general precautionary 1STUD, brs-grd 1/4-20x 1-3/4 1NUT, brs-hex jam 1/4-20 3PANEL, front-w/components 1RESISTOR, WW adi SOW 10 ohm 1REACTOR, (consisting of) 1..COIL,LH 1

COIL, center 1..COIL,RH 1FRAME, mtg-reactor and stabilizer 1STRIP, mtg-transformer 1TRANSFORMER, control-idle 1STABILIZER 1STRIP,adhbackl/8x1x27-1/2 2

605 288 . . FITTING, pipe-plug sq hd 1/4NPT 1SPM-449 Page 4

Item Dia.No. Mkgs.

PartNo. Description Quantity

Figure 1. Main Assembly (Continued)

010021 . CLAMP, stl 9/l6diaxll/32 hole 2045 158 - . KIT, label 1

*Recommended Spare Parts.+When ordering a component originally displaying a precautionary label, the label should also be ordered.Effective w/KA775726, these items are no longer included w/engine.Effective w/KA775726, for replacement parts contact Factory Service Department.BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.

TD-007 287-A

Figure 2. Generator

111

8

5

23

25

SPM-449 Page 5 Big 20

Item Dia.No. Mkgs. Description

1

2

3

5567

..9. R4, 10

- . 11 .

1213

. 14 ....-. 15

16 -.

17181920

-. 2122

-. 22232424252526272829293031

VR1

Dl....ALT

Figure 2. Generator (Fig 1 Item 59)

010 118006 047602 178005 572005 755046 462106431106425037 306000 901048 420046 455106 641106 426046 819124 593

+079 927013367005 796006 096024617053 390005 797035 775006 712005 450005 765605 430061 441005 799106 441004 994003 923047 885004 993047 879

*049 125005 614005 745046 459106 432106 425037 305000 901048 420046 455106 641

KEY, 1/4x1/4x1/2PULLEY, V (consisting of)

SCREW, set-skt hd 1/4-20 x 3/8BELT, V-notchedENDBELLDIODE ASSEMBLY, RP (Prior to JGOOO5O1) (consisting of)DIODE ASSEMBLY, RP (Eff w/JGOOO5OI) (consisting of)

... INSULATORDIODE, 15OA300VRP

.... CAPACITOR, (Eff w/HK338344 thru JGOOO500)

.... CAPACITOR, (Eff w/JGOOOSO1 and on)... CAPACITOR, (Eff w/HK338344 thru JGOOOSOO)

CAPACITOR, (Eff w/JGOOOSO1 and on)INSULATORSUPPRESSOR, (Effw/JA440199)EDGE TRIM, 62-1/16 black w/clipsSTATOR, generatorLABEL, warning moving parts can etcBAFFLE, air-generatorROTOR, generator (consisting of)

.... RING, retaining-ext... BEARING, ball

.... FAN, rotorKEY,3/8x3/8x1-1/2

SUPPRESSOR, surge excitationALTERNATOR, 37A 12VBRACKET, mtg-alternatorPULLEY, single beltSTRAPBARREL, rect (Prior to JGOOO5O1)BARREL, rect (Eff w/JGOOO5O1)BRACKET, mtg-brushholderCAP, brushholder (Prior to JA365784)CAP, brushholder (Eff w/JA365784)BAR, retaining -brushholder (Prior to JA365784)BAR, retaining-brush holder (Eff w/JA365784)

- BRUSH, w/springHOLDER, brush-w/tabsBRACKET, mtg-brushholderDIODE ASSEMBLY, SP (Prior to JGOOOSO1) (consisting of)DIODE ASSEMBLY, SP (Eff w/JGOOOSO1) (consisting of)

INSULATORDIODE, 150A300V5P

.... CAPACITOR, (Eff w/HK338344 thru JGOOO500)

.... CAPACITOR, (Eff w/JGOOOSO1 and on)

.... CAPACITOR, (Eff w/HK338344 thru JGOOO500)CAPACITOR, (Eff w/JGOOOSO1 and on)

*Recommended Spare Parts.+When ordering a component originally displaying a precautionary label, the label should also be ordered.BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.

SPM-449 Page 6

PartNo. Quantity

11111123221151111111111111111112211221

1

Big 20

Item Dia.No. Mkgs. Description

Figure 3. Bracket, Mounting-Power Output (Fig 1 Item 77)

...NEG...

.6..

10111213

POS

039 046601 879039 044601 880039 045601 976039 047601 976039049601 880039 044601 879

108 127 .. BRACKET, mtg-term pwr outputTERMINAL, pwr output (consisting of)

NUT, hex-full 1/2-13....BUSBAR ... NUT, hex-jam 1/2-13.... TERMINALBOARD,black

SCREW,cap-hex hd 1/2-13 x 1-1/2TERMINAL, pwr-output (consisting of)

.... SCREW,cap-hex hd 1/2-13 x 1-1/2TERMINALBOARD, redNUT, hex-jam 1/2-13

....BUSBAR

.... NUT, hex-full 1/2-13

TB.048 150.8

Figure 3. Bracket, Mounting-Power Output

BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.5PM-449 Page 7

PartNo. Quantity

.1

.1

.1

.1

.1

.1

.1

.1 1.1.1.1.1

2

1

8

Big 20

Item Dia.No. Mkgs. Description

Figure 4. Panel, Front w/Components (Fig 1 Item 81)

...8...CB1

...9...RCl

10 ... 5110 ... 5111 .. PBl12 . . .S413 .. PCi1415 .. R5....16 .. Cl ....1718

19192021

019 754010 836

081 484005 015114 193005 890005 355079 560604 176073 690011 609011 611011 767011 609071 609084 274072 634046 656072 633005 789602 178019790071 646082 788082 789

22 . PL1,2.. *048155

1

HANDLE, range switchPIN, spring-compressionNAMEPLATE, (order by model and serial number)PANEL, frontSWITCH, range (Prior to JH257160) (Fig 5)SWITCH, range (Eff w/JH2571 60) (Fig 5)STRIP, friction-rheostatRHEOSTAT,WW5OW9ohmCIRCUIT BREAKER, man reset 25ARECEPTACLE, straight-duplex grd 2P3W iSA 125PLUG, str grd armd 2P3W iSA 125V P&S 5266 DFSWITCH, tgl SPST 20A 125V (Prior to JC607457)SWITCH, tgl DPDT 1 5A 1 25V (Eff w/JC607457)SWITCH, PB starterSWITCH, tgl SPST 20A 125VCIRCUIT CARD, weld/idle control (Fig 6)CAPACITOR/RESISTOR, (consisting of)

RESISTOR, WWfxd 25W 50 ohm.... CAPACITOR, ignition .Suf

BRACKET, mtgHANDLE, rheostatSCREW, set 1/4-20 x 3/8CONTROL, push/pull (Prior to JJ335442)CONTROL, push/pull (Eff w/JJ335442)HOLDER, light

. LENS, light-redBULB, incand 12V

PartNo. Quantity

1

1111111111111222

Tc-007 288-F

10

Figure 4. Panel, Front-w/Components

BE SURETO PROVIDE MODELANDSERIAL NUMBERWHENORDERINGREPLACEMENTPARTS.Big 20 SPM-449 Page 8

Description

Figure 5. Switch, Range (Fig 4 Item 5)

BRACKET, mtg switch (Prior to JH2571 60) (consisting of)BRACKET, mtg-switch (Eff w/JH257160) (consisting of)

SPRING, extensionLOCATOR, quadrantCONTACT BOARD ASSEMBLY, switch-range (consisting of)

.... GUIDE, contact board-movable

.... SHIM, guide-contact board

.... CONTACT BOARD, movable switch

.... CONTACT BOARD, stationary

.... CONTACT ASSEMBLY, movable (consisting of)SPRING, pressureCONTACTSPRING, pressure

.... CONTACT, stationary

TB-Oil 273

1

Figure 5. Switch, Range

BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.5PM-449 Page 9

ItemNo.

PartNo. Quantity

011 322114 235010 671017 428004 998100 623011 012011 980004 999011 645011 076011 953011 074011 644

.7

.8

-. 10 . 11

1213

11113322312

115

TB-Oil 100

Big 20

Dia.Mkgs.

PartNo. Description Quantity

PCi 071 609 Figure 6. Circuit Card, Weld/Idle Control (Fig 4 Item 13)

CSO,54 035 522 . . CAPACITOR, mylar .047uf iOOV 2C51 52 045 868 . . CAPACITOR, tantlm iOOuf 25VDC 2

C53 080 507 . . CAPACITOR, tantlm 22uf iSV 1D50,54 070 250 . . DIODE, 3A 600V SP 2

DSi-53,56,57 .. 026202 .. DIODE, 1A400VSP 5DSS 037243.. DIODE,zenerl8ViW 1Q50 000 088.. TRANSISTOR, 800MA 40V iQ51 039 355 . . TRANSISTOR, unijunction 1 5MA 40V 1

R50,53 000 039 . . RESISTOR, C 2W 680 ohm 2RS1,56 605919.. RESISTOR,C.25W47ohm 1

R52 605 916 .. RESISTOR, C .25W 1K ohm 1R54 035 824 . . RESISTOR, CF .25W 270 ohm 1R57 052 146 .. RESISTOR, CF .25W 620K ohm 1R58 053 572 . . RESISTOR, CF .25W 12K ohm 1R59 052 138.. RESISTOR, CF .25W 20K ohm 1R60 035 822 .. RESISTOR, CF .25W 10 ohm 1

R61 ,62 030 026 .. RESISTOR, C .5W 560 ohm 2R63 003 272 .. RESISTOR, CF .25W 1 meg ohm 1R64 071 595 . . RESISTOR, CF .25W 22 ohm 1R65 000 885 .. RESISTOR, MF .25W 10K ohm (Eff w/HK255727 thru JA440662) 1

SCR5O,51 . ... 080 508.. THYRISTOR, SCR 8.5A 200V 2SR5O 021 939 . . RECTIFIER, integ I .5A 400V 1

080506.. HEATSINK,dual 1

A B C D E F H J

Don 0 0 II 0 000

5.090 506

Figure 6. Circuit Card, Weld/Idle Control PCi

BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.Big 20 5PM-449 Page 10

Item Dia.No. Mkgs. Description

Figure 7. Panel, Open Circuit (Fig 1 Item 69)

...1...CR2

...2...5R2.3 .. R3

...4... D8

6.7

..8...TEi910

- . 1112

.13.. C8.

059 267035 704030 844

... 034 502

... 074 230

... 085 380603107038621

... 038 620

... 053 967

... 081 499010143

... 031 651

RELAY,12VDCDPDTRECTIFIER, integ 40A 800VRESISTOR, WWadj 25W25 ohmDIODE,zenerl2VSOWHEATSINK,rectSTRIP, mtg-diodeHOSE, 5/32 ID x 11/32 OD (order byft)BLOCK, term 30A 4 poleLINK, jumperINSULATIONBRACKET, mtg-strip termCLAMP,3/8diaCAPACITOR, tantlm 68uf 2OVDC

PartNo. Quantity

111111

ift121111

.6

13

7

1

TB-046 933

Figure 7. Panel, Open Circuit

BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.

SPM-449 Page ii Big 20

Dia. Part

Mkgs. No. Description Quantity

Parts For Optional Equipment

041 138 . . METER KIT, amp and volt (consisting of) 1A2 046 651 .... METER, ADC 5OMV 0-400 scale 1V 046654.... METER, VDC 0-100 scale 1

Shunt 030 080 .... SHUNT, meter 5OMV 400A 1000 915 . . METER KIT, running hour (consisting of) 1

HM 145303.... HOURMETERKIT I006 122.. RCGD-40A REMOTE CONTROL FACILITIES, (consisting of) 1

S7 011609.... SWITCH,tgISPDTi5A12SV 1RC3 032 897 . ... RECEPTACLE, twlk-grounded 2P3W 125V 1

034 508 . ... CONNECTOR, block 30A 45 deg 2041 329 . . AUXILIARY POWER, 240V (consisting of) 1

RC2 604 103 .... RECEPTACLE, straight-duplex grounded 2P3W iSA 250V 1025 234 . ... CAP, straight-grounded 2P3W ISA 250V 4041 397 . . LOW OIL & HI TEMP SHUTDOWN, (consisting of) 1

MS1 011 072 . ... SWITCH, magnetic (consisting of) 1F 048317 FUSE, minatgl 14A32V 1

005 775 . . POLARITY SWITCH, (consisting of) 1S2 006 401 .... SWITCH, plrt (consisting of) 1

011 948 GUIDE, contact-movable switch 2038 769 CONTACT BOARD ASSEMBLY, switch-plrt 1024 694 BEARING, switch-plrt 1103634 MOUNTINGBOARD 1103 633 BUS BAR, shoring-switch plrt 2010 082 TUBING, stl 5/8 x 5/32 wall x 1/2 2006398 HANDLE 1019 603 KNOB, ball 1038 311 . . INSULATOR, switch-plrt 1041 056.. FA-iG FLAME ARRESTOR FUEL CAP 1040 68S . . EM-6 EL MOD, (consisting of) 1010 429 . . . . JET, carburetor high altitude 1061387.... GASKET 1

BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.

ELECTRICAL DIAGRAMS

Table 1. List Of Circuit Diagrams And Wiring Diagrams

The following is a list of all diagrams for models covered by this manual. To order diagrams needed, proceed as follows:

1. Know unit Model and Serial or Style Number.2. Use List to find diagram number.3. Call the Technical Publications Department at 414-73S-43S6.

Model Serial Or Style Number Circuit DiagramBig2O HJ213165 thru HK250617 B-081451

HK250618 thru HK338342 B-048 315-BHK338343 thru JA4401 99 B-046 425-AJA440200 thru JB578644 B-072 430-AJB578645 thru JC607456 B-085 032JC607457 thru KA775725 SC-085 300-CKA775726 and following SC-136 362

Circuit Board PCi HJ213165 thru HK255726 A-080 739HK255727 thru JA440662 A-081 887JA440663 and following SA-071 600-A

Not included in this manualBig 20 SPM-449 Page 12

w

~:~0~

w UJ~,0

CU

z

DoDWC-

LCD

DO

0.JD C.)

0

IL

C

(0

6z

I..0)

4-

0)

0)

uJ0c%J

mI-0U-E(U1..

(U

C.6~

0a-

(3

0)a-

iz

0,

0,

6U,

D

U,

I

Big 20 SPM-449 Page 14

052DIODEISOLATED 0

RESET

POSITIVE B

OUTPUT(DELAY OFF) C

RESET &BURDEN E

RESISTOR

F

CT

H

NEGATIVE J

Figure 10. Circuit Diagram For Circuit Card Weld/Idle Control PCi Effective WithSerial No. JA440663 And Following

OUTPUT

(DELAY ON)

A

055

5A-071 600

5PM-449 Page 15 Big 20

Main AssemblyParts List

GeneratorParts List

Bracket, Mounting-Power OutputPanel, Front w/ComponentsSwitch, RangeCircuit Card, Weld/Idle ControlPanel, Open CircuitCircuit Diagrams And Wiring Diagrams