Question about Miller Welding Tools

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Ground lead arcs when I connect, and auto idle kicks up

Whenever I connect the ground lead it arcs and the engine speeds up like I'm welding, but I can't weld. Its like both leads are hot.

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  • kkbolejack Feb 07, 2009

    machine is mounted to a truck and welding is being done on the workbench on the back. ground lead is attached to the metal I'm welding. Problem just started after 600 hours of welding with this setup.

  • Anonymous Mar 21, 2014

    When you touch wire to metal it arcs everytime without pulling trigger, but no wire feeds

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  • 11 Answers

Hi
what are you connecting the ground lead to?

Is the welding machine phisicaly in contact to what you are welding ?

Can you electrically insulate the welding machine from everything, say stand it on a sheet of timber?

Regards
Rob

Posted on Feb 07, 2009

  • Robert Lee Feb 08, 2009

    Hi

    try welding off the truck, so run some welding cables so that everything is isolated from the truck.

    does the welder opperate normally now?

    if it does then someware there is a short between the "hot" terminal of your welder and the chassis of the truck,

    so when you connect the ground cable to the bench( which is the chassis of the truck) the welder "thinks" its welding.



    does the welder have an aux supply for power tools?

    if there is anything pluged into this is it faulty take it out



    do you have a test meter (Volts, Amps, Ohms)?

    this would help in tracing the fault.



    are the welding cables in good condition, no bare copper showing along their length?



    try al this then come back to me



    regards

    rob



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Tip

How to set ark welders with more than fifty foot of welding cable



This tip is referring to welding machines using fifty foot add on sections of welding leads.
Number one: Set the machine with just the stinger whip(six to eight foot long) and a fifty foot ground lead.The ground lead can be shorter.
Number two: Get a piece of scrap plate the same thickness as you will be welding.
Number three: Set the plate in the position you will be welding in and clamp the on ground to to plate.
Number four: Turn on machine and set amperage dial to the size of rod.(if your using 1/8 rod set for 125 which is the decimal equivalent of 1/8) using decimal equivalents will get you in the ball park but depending on the coating , thick or thin you will have to adjust from there.
This will work for rods like stainless that have high resistance to current.
Number five: Once you have the setting that you like add five amps for every fifty foot of lead your using.This works for copper leads that are half inch thick and that all connections are tight. One more thing,if the rod is eating a crater ahead of the arc your running to hot.

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