I have a millermatic 200 and if i lay the ground lead on the welder it arcs.tested the ground lead and found the ground lead has about 16 volts going through it. it welds good as long as i have the work on the ground.
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Re: the ground clamp has voltage
WARNING ! You have an earth leak on the unit, before you do any more work with this set, have it checked by a qualified electrician, it can be HIGHLY dangerous to continue. the leakage can be on the mains side and can cause you serious injuries. dont atempt to repair or examine yourself.
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Most of these machines (would have to have serial number to be sure) will not feed if their is no output voltage, since part of the motor voltage comes from the arc voltage.
So, I would suspect broken wires, either in the work lead or the gun. If it arcs just a little, probably the gun. One place the work lead breaks is right at the back of the clamp. Pull on the insulation and see if it "stretches". If so, the wire there is broken.
If everything is connected according to manual, then your problem must be contact box inside the machine. If it is a recent model 2005 or higher then it could be the main pc board. I would start by checking the ground cable and clamp first before send it to a repair shop.
Your windings inside are aluminum, they may have loosened up where the positive lead hooks on to the transformer inside.
I had a miller and the wire melted there, you can re-loop the wire and re-fasten it if it melted short enough if this is infact the the problem when you take the cover off..
Turn off welder, unplug and press trigger to discharge any possible stored juice. Then, open side door and check the ground cable where it connects inside, it sounds like either ground or the hot is off. Once you determine those are both securely attached, close door, plug in power on, attach ground clamp to test piece off metal and try it again. Let me know if this helps! Thanks:)