Miller Blue Star 1E Wiring Problem

[handymanheb]

Joined forum today hoping to find help with a wiring problem on my welding machine. Welding machine is a Miller Blue Star 1E. Serial number HK228119. It has a Kohler engine model K341S, Spec. 712520 Serial Num. 93497. The serial number could be wrong as it was scratched near the end and I could have copied wrong. First four numbers are correct.

We have had this welder on our ranch for years and years and it has worked well through the years until I loaned it to a neighbor. When it was returned to me I did not examine it as I figured he would tell me if it had a problem. When I went to weld the next time it would not idle up when I struck an arc. When I examined it I noticed the two wires (white)going to idle module were cut in two along with two other wires that are encased in a wire protector. (dark blue) I have not idea where these two wire go. From their location and orientation they appear to have gone somewhere on the side or front of the engine.(Engine cranks and runs fine)

I am a rancher, not a welding expert or electrician. I know a little bit about a lot of things but not a whole lot about anything specific. I have read you guys treads and can tell you know what you are talking about. I am hoping one are several of you could point me in the right direction on where to hook these wires back up.

Obivously I will no longer be loaning out my equipment to that neighbor!

Thank You in advance for any help!

Eric

[razer]

Maybe you could post some pictures?

Here's the manual.
http://www.millerwelds.com/om/o423g_mil.pdf

I think the info you're looking for is on page 16 in the manual, (20 in the pdf)

I have posted the relevant schematic from the manual.
It doesn't talk about wire colors, but you should be able to figure out what's what from knowing how many wires go from where to where.

[handymanheb]

Miller Blue Star 1E wiring problems. Thank you for your help Journeyman. As I am not very good with schematics I will take a few photos tomorrow after I eat the turkey and post them. I had not thought of that but it is a great idea.

Again, Thank You and have a great holiday!

[handymanheb]

I did some more research on my BlueStar 1E and I think I have enough information now that you guys can probably point me in the right direction. I have a good photo of the wiring but I do not know how to attach a photo on this website. The two blue wires are broken and terminate into the air right near the manual throttle for the engine. (near the dipstick) One of the dark blue wires runs back to the "Weld Power Switch on the front panel and the other dark blue wire goes into the generator motor windings. It appears as though there might have been some type small assembly bolted to the flywheel cover on the engine, right below the manual throttle. There are two small bolts there and I can see that something was once fastened there. I think maybe the blue wires went to that. If this helps at all I could sure use the help as I now think there is something missing and that is why I cannot find where these wires terminate.

Thanks!

[razer]

Maybe the neighbor took something off of the machine? The idle solenoid maybe?

You have a photo on your computer?
To post pictures, click on "post reply" on the left, just directly below the last post.
There will be an orange button that says "Manage attachments", click on it.
There will be a box just below where it says "Upload File from your Computer".
There will be a button just directly to the right of that box. Click the button, and find the picture you wish to post, and double click on the picture. Then click on the orange button that says "Attach", wait a moment for the file name to show up below. Repeat as necessary for each image, and then close the window. You can wire tour message and post as normal.

[duaneb55]

Sounds as though the throttle switch (closes for POWER mode) is missing.

[handymanheb]

Thank you razer and duaneb55 for you guys help. I believe you have solved my problem. I took the numbers from the two blue wires and compared it to the schematic razer sent me and I believe it is the very switch duaneb55 mentioned. On the schematic posted by razer it is identified as "S2 Power". Is this just a simple switch that I could buy and install in the same location or is there more to the switch than that.

Again, thank you guys for your help!!

[handymanheb]

Forgot to mention the wire numbers. The two dark blue wires are #18 and #13.

[duaneb55]

Your previous description was enough to identify those two wires.

This http://www.mcmaster.com/#micro-switches/=f5z7nt is the type switch usually seen used for throttle switches. The actuator type is based on how the throttle is configured to control the switch.

[handymanheb]

duaneb55,

Can I install a single pole switch at the location where the other one was removed and solve the problem, or is it a more complex switch? I am not big on electrical work but can do basic wiring if I need to. However, I know enough to never try to connect a wire to something I am not completely sure about. I do not want to fry something. Could sure use your comment on this and I should be finished.

Thanks!!

Eric