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miller 225G plus will arc but no weld

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3.2K views 12 replies 5 participants last post by  monsoon-mech  
T
#1 ·
Help!! I have a 225G plus (serial # KF979609) (Stock # 903372). Just got welder. Runs great but no weld output and auxiliary is only putting about half of the voltage. Removed sheet metal and cleaned with compressed air. Will make small arc with rod. I would like to know if there is a PDF manual that would have trouble shooting steps. I am a heavy equipment mechanic with 32 years experience. I am proficient with electrical problems and would like to make my own repair. Just need a starting point.
Any info would be greatly appreciated.
Thank you
 
#2 · (Edited)
If it's a 240 volt machine are you getting 120 on both legs of the power, should be 120 volts to ground on both legs or 240 volts leg to leg. I have an ancient machine that started acting up and it was one side of the switch was dirty and not allowing one leg to the transformer, it would tickle spark, as soon as I got the switch cleaned it was back to normal.
 
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M
#6 · (Edited)
First is corrosion on slip rings its oxidation and will develope depending how humid your area is if the welder isn't ran for long periods to clean correctly ya needa have the machine running, I put some 600 grit allum/oxide paper over the end of a dowel and lightly touch to each slip ring till shiny... , next the course adjustment contacts its common for the old dieelectric grease to harden and actually become an insulator clean contacts with acetone and either cotton swabs or piece of rag over a flat screw driver blade.. do not sand as ya will only create gouges etc.. after clean put new dialectric grease on contacts and rotate through all ranges do same for AC/DC selector.... but if your aux. is low too its most likally slip rings are oxidized... they are copper they can't "rust"

Edit; BTW don't forget to clean polarity switch contacts too
 
#8 ·
I didn't realize this was a gas powered machine when I posted to check voltages. Sorry!!
 
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#9 ·
OK Guys cleaned slip rings. brushes free. Checked both fuses and cleaned holders. Cleaned fine adjustment. Cleaned contacts on course adjustment. No change in operation. Should I take course adjustment switch and selector switch apart and clean. Called MILLER to find out where to find technical manual, they told me to contact my local dealer. Called local dealer, they told me to contact MILLER???? machine only has 125 hours showing and is in good shape. Any other suggestions ?
 
M
#10 ·
if ya cleaned the contact surfaces on course adjustment )using acetone and swab to get between each set as ya rotate the knob to open each) and slip rings are clean then nothing to be gained taking them apart now all ya have left is a bad board.... the tech manuals are based on serial number a member here "Duane" is pretty good at finding em.. ya might wanna post this or get a mod to move it to the MILLER forum lower down the menu in manufacture specific area
 
S
#11 ·
Miller is good at helping trouble shoot tech problems. They should be able to put you in contact with one of their guys who is experienced with this machine. They can walk you through some checks. Don't ask them for a tech manual, ask to speak with a tech support guy to help trouble shoot your machine.
 
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