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An unstable arc when stick welding can be caused by a few different things. Here are a few things you can try to fix the problem:
Check the electrode holder and make sure it is clean and tight. If it is loose or corroded, it can cause an unstable arc.
Check the ground clamp and make sure it is clean and tight. The ground connection must be secure for a stable arc.
Check the welding cables and make sure they are in good condition, not damaged, and that the connections are tight.
Check the welding gun and make sure it is clean and in good condition.
Check the welding settings, and make sure they are appropriate for the type of welding you are doing. Make sure the voltage and amperage are set correctly.
Check the welding rod, if it's too short, it could cause an unstable arc.
Check the engine, and make sure it's running smoothly and that it's producing enough power.
It's important to check the manual of the welder for troubleshooting steps and also check the warranty of the welder and see if it's still covered by the manufacturer. If you are not able to find the problem or if you are not familiar with welding equipment, it's best to take your welder to a qualified Miller Electric welder repair service center, they will be able to diagnose and fix the issue.
If your Miller Bobcat 250 runs great, the generator works, but the welder will not weld, even though the fuses are good, it could be caused by a few different things. Here are a few things you can try to fix the issue:
Check the welding settings, make sure they are appropriate for the type of welding you are doing. Make sure the voltage and amperage are set correctly.
Check the ground connection, make sure it's clean and tight. The ground connection must be secure for stable welding.
Inspect the welding cables and make sure they are in good condition and that the connections are tight.
Check the welding gun and make sure it's clean and in good condition.
Check the main contactor and make sure it's engaging and disconnecting properly.
Check the main circuit breaker and make sure it's not tripped.
Check the power output of the generator and make sure it's within the correct range.
Check the control circuit and make sure that it's not damaged or malfunctioning.
It's important to check the manual of the welder for troubleshoot steps and also check the warranty of the welder and see if it's still covered by the manufacturer. If you are not able to find the problem or if you are not familiar with welding equipment, it's best to take your welder to a qualified Miller Electric welder repair service center, they will be able to diagnose and fix the issue.
There is something wrong with the auto load sensing switch which is part of the generator. That is the sensor that detects when current load from the generator drops as in when you strike an arc or turn on a power tool and cranks the throttle to full power. It is obviously working on manual because the manual switch is cranking the revs up so the solenoid that operates the throttle is ok. My advice is to take it to a service centre that deals in welder/generator sets as you are playing with dangerous voltages and may possibly damage the machine by tinkering with it or fry yourself (nasty)
If your battery is in good condition (check this one first, take it to your nearest autozone they'd do it for free) then you need to replace the voltage regulator, this one is located on the back of the unit under the back cover of the main engine, it looks like a black rectangle with two cables. For teh second problem, check your fine voltage button and increase it as needed until the rod does not stick to the metal, but not higher enough to pierce or burn thru it.
Is this on new rods as well as one's you'be been already welding with? Depending on rod types, some will "flux over" the end, after welding insulating the tip. When you're welding at a low setting, with a small rod, sometimes it is hard to start an arc. A 7018 rod is a good example of this. Strike the rod like a woodden match, or drag it on the metal, to expose the rod. It also depends on your welder. Some have settings to help start an arc and then control the current. Older transformer welders arn't that smart and are less forgiving on low current thin metal settings.
Arc blow could be the cause! Put your ground on the work piece and weld away from it. If you weld toward a ground clamp the magnetic forces will blow your arc around sometime. When taking a cert this simple mistake can make or break ya on your cap or reinforcement beads.
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