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Millerwelder-legend aead 200le runs but will not idle up or weld replaced sol. checked board under bonnet 1 ***. has plastic peeled off ! sr# jk 695949

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Posted on Jan 02, 2017

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SOURCE: serial number miller AEAD 200LE JF 885778

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Posted on Jan 13, 2012


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Miller legend 200le

All welders have what is caller a duty cycle switch that becomes hot expands and disengages the welder unit. Much like a thermostat works. It may well be that yours is defective. If you are handy you could do an R&R yourself. First you need to observe that this is your problem. If you are able to reset the unit after some cooling or the unit resets itself this R&R should correct your problem.

Feb 02, 2014 | Welding Tools

1 Answer

Out in Afghanistan using the 302 and when i press the trigfer to start mg welding the power supply to the remote unit cuts off. any suggestions?

If it is only momentary, it may be sand in the contactor- blow unit clean or as best you can and "tent" some poly plastic over the contactor with duct tape to seal it to cabinet. Use the heavier 6 mil stuff or fabrcate a cover from phenolic sheet or fishboard (flame proof material looks and feels like cereal box cardboard)- old circuit boards from derilect equipment, etc also can work, the idea is to dust proof the contactors- the heavy one especially.. Check to make sure it does not melt either as it will get exrra warm there. They were made for a metal shop not a desert. No offense intended.

Also check to make sure the circuit breakers CB1 and CB4 are sound- they can fatigue fail and/or wire connections work loose and become intermittent under load.. Also cycle the switches a few times to clear the crud. If you have LPS1 available- it can help clean the contacts and dries without residue.

Also check the trigger switch and replace it if you can find no other obvious faults with an ohm meter. If not, the microswitch might come apart to clean up the contacts. It "might" even be interchangeable with.derilect mcrowave interlock switches- which would need to be sealed with silicone out there.

If you do not have the manual for it from Miller, you can download it from their website
then just scroll down to the flavor of 302 you have. Engine controls are the only real difference between the three models

Lesser possibilities are an issue witht he current sense coil- PLG-6 attaches there- also check that connection. They would be wires 141, 142, 143, 144 They go to the main board.

Also check RC-12-1 and RC-12-3 these will be on the PC-2 board- they are the voltage sense wires and they go to switch 1.

Also check SR-1 the rectifiers- make sure they are not loose or have faulty soldering- this can drop out the voltage too.

Sep 20, 2012 | Miller Trailblazer 302 Welder Generator...

1 Answer

Hi I have a 94 del sol 1.5 when its in gear and your driving around 1500rpm it starts to **** and if I ride the clutch it idles up and down but at idle not in gear it runs smooth

difficult one this ,its a manual so this obviously not a american version ,To be honest here this is one of them questions where i would need a road test i think to see first hand the problem,Their is a multitude of things that could cause this ,the idle with foot off the clutch could be the crank thrust bearing are worn causing a resistance ,to check this get someone to push the clutch down and you check the front pulley to see if it moves forewards when clutch is pushed down ,now as for the missing at 1500rpm this may just need the plugs regapping to 25 th but it could also be a mass air flow sensor even a coil pack and without head under bonnet i have no idea

Mar 30, 2012 | 1994 Honda Civic Del Sol

1 Answer

I have a Miller big 40 bout an 87 modle that runs and welds great but wont idle down. Any thoughts?

There is a solenoid that controls the idle speed and the run speed- it is stuck in run speed. It may be a binding linkage, it may be bypassed by a previous owner.Chances are, as the idle relay is controlled through a load sensor on the control board and it may simply be a wire is off, damaged, or the solenoid is stuck.

There were a few different engines available for that model so exact connection will vary,

This the main manual
The manual for the engine option you can scroll down to the "Big 40" in the list and just below that are the manuals for the different engines used.

Mar 26, 2012 | Welding Tools

1 Answer

Serial number miller AEAD 200LE JF 885778

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Jan 13, 2012 | Miller Welding Tools

1 Answer

I have a syncrowave 250, it is about 12 years old. I bought it new and use it rarely. Recently I went to weld some light aluminum and when I tried to start an arc,it acted as though I had no ground...


I would like to suggest to you that you post this question on the millerwelds forum. There are some very experienced tech guys there that can help you much better. Go to and select the forums under the resources tab. You will be surprised. Hope you can get it running again.


Mar 27, 2017 | Miller Electric Manufacturing Electric...

2 Answers

1994 honda del sol idle problem

check your cable that runs ur throttle and follow it at the end it has a plastic piece, my friend had a honda del sol and the plastic piece was broke causing the cable to come loose sometimes and idle high then drop then high then drop etc. just a thought

Aug 01, 2010 | 1994 Honda Civic Del Sol

1 Answer

Need schematic for Miller AEA200LE

Go to "" and enter you model number in the search on the home page at the bottom, right hand side. This takes you to another page and you can fine tune what you are looking for.

Good luck and hope this helps.

Mar 13, 2009 | Welding Tools

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