Question about Miller RENEGADE 180 WELDER GENERATOR MIG 907395

2 Answers

Spool wire starts to melt while on the spool

I have a Miller MIG 90 I believe, purchased in the early 1990's, it is the model that was replaced by the Model 135.
I was welding one day, and wire stopped coming out. So I popped the hatch and found the wire had broken (or melted) before going into the liner. I did smell something hot, but I was welding, so of course things were hot. I set up the machine again and pulled the trigger. Once again the wire wouldn't come out. So I quickly popped the hatch and saw that the wire and several windings on the spool were glowing. It actually melted the plastic guide leading to the liner.
Any help is appreciated!

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  • 27 Answers

You have a dead short.
take it to qualified repair center and dont kill yourself trying to find it.
not a phrase-dont be dead.
just take it to a pro.

Posted on May 09, 2014

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1] Switch off the mains power,remove the torch from the machine,ther should be a button or switch on the unit to feed the wire, push or switch these and observe that the wire feeds and dose not heat up, if ok then you have a short in the torch, a new torch assembly is required,if the wire heats up with the torch removed, the wire spool is shorting out, remove the spool and check wiring in and around the feed motor, if you can't see anything check for a voltage from a good earth and on the rollers, if you have a voltage then the motor is faulty.(earthing out) a P.A.T test should show exactly where this is.

Posted on Feb 16, 2009

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