Electrical connection

[danny53]

The electrical plug for the mig gun is not getting a good connection. Ever so often the connection will lose the connection.
Any suggestion of what I can do without having to replace it? I have a Millermatic 140.

[BaTu]

What do you do to fix that "bad connection"?

Is this in the plugs receptacle or in the plug itself that you think it's happening?

[Broccoli1]

I'm not sure how it could lose connection at the machine side as it locks in place.

perhaps a loose connection inside the gun at the trigger.


You can open it up and check.

[danny53]

When it stops working, I unscrew the connection take it out and put it back in. Fixed the problem, may have to do it more than once. That is why I think its in the connection to the welder rather than out at the gun.

[BillE.Dee]

I unscrew the connection take it out and put it back in

what connection are you referring to? Is it where the whip slides into the machine? If so, do you have it all the way into the seating area and the retaining bolt tightened? Are all of the wires inside the cabinet clean and tight? Is this a new machine or new to you? Does this situation happen after any particular operating time frame?

[CAVEMANN]

put some pressure either up or down with a bungee cord & see if it fixes it t
hen at least you'll have it narrowed down some.

[MinnesotaDave]

Jiggle test.

Next time it won't go, keep finger on the trigger and wiggle wires until you find where the problem is.

[ccawgc]

one of three things, first the trigger wire is broken inside the plug.
remove the cord clamp and unscrew the back shell. see if the wires are broken or twisted up. the pins are replaceable, but it take special tools. a pin extractor and a AMP pin crimper. plus new pins. some times the pins do push back into the plug.
you can carefully pull the pin back out and lock it is place. If plug and wire are damaged you can buy from Miller a new trigger cord that is a short cord with the plug installed. You just open the miggun back handle and butt splice the cord to the old wires inside and close up the handle. Looks like new.
Third problem is a problem with the receptacle. the socket could be push in or damaged so it is to large to contact the pin. You can try pushing it from the back side into the correct position. for to large you can some times use a very small screw driver and shrink the socket so pin makes a good connection.
Use an ohmmeter and test pin to pin on the trigger plug. should be open then closed when trigger is pulled. When you see the closed circuit. move cord around and see if it is broken.