Rehab of a very tired Millermatic 200..

[Ps91-rick]

So I was able to get some fresh cable to replace my not very good condition cable that is used to select high or low power on the front of the machine.. I went to a local welding shop and they claimed to not have any..??? So I went down the street to Napa and got it there.. it wasn’t 4 gauge but 1... kinda spendy at $10/ft but I only needed a few feet..

I’ll keep looking for a place to get the ground clamp wire .. if that’s #4... it’ll be a bit smaller than the #1 I just bought. Anyway, I’ll have to get a few more bits here and there before I can start on it again. Thanks all!

[Aeronca41]

https://www.ebay.com/itm/EXCELENE-4-...cAAOSw-0xYbWM8

Less than $2 a foot; free shipping. I've bought some of this for my Lincoln Idealarc--nice stuff.

[G-ManBart]

https://www.ebay.com/itm/EXCELENE-4-...cAAOSw-0xYbWM8

Less than $2 a foot; free shipping. I've bought some of this for my Lincoln Idealarc--nice stuff.

I've bought from them multiple times....very good quality stuff. I made a set of heavy jumper cables and leads for my engine drive with their cable....flexible, made in the U.S. and smells nice.

[Ps91-rick]

I just ordered 15’ in black for the ground strap.. thanks!

[Ps91-rick]

Ok.. I need the black receptacle that the negative cable plugs into. I appears that the original part isn’t available anymore.. part #039-826 .. anyone know of an alternate equivalent..?

[G-ManBart]

Ok.. I need the black receptacle that the negative cable plugs into. I appears that the original part isn’t available anymore.. part #039-826 .. anyone know of an alternate equivalent..?

When I get part numbers like that I usually run them on Millerserviceparts.com or Miller4less.com to see what I find and they usually list when a part has been updated. The new part is:

https://www.millerserviceparts.com/P...?productId=971

Here's the old part with the new reference:

https://www.millerserviceparts.com/P...?productId=976

[Ps91-rick]

Got it! Thanks!! I did search on miller4less but got no items found.. and did run across the site you mentioned but wasn’t sure if what came up was the new replacement or not as I was on my phone and it wasn’t obvious.

my last question for today..,the spool wire guide inlet.. it’s shown on my parts diagram but has no part number listed. This is the brass piece with the pointed end that feeds the wire into the drive rollers.. mines seen better days and if it’s a replaceable part, I was thinking of changing it out since I’m ordering a few parts anyway..

thoughts?

[G-ManBart]

my last question for today..,the spool wire guide inlet.. it’s shown on my parts diagram but has no part number listed. This is the brass piece with the pointed end that feeds the wire into the drive rollers.. mines seen better days and if it’s a replaceable part, I was thinking of changing it out since I’m ordering a few parts anyway..

thoughts?

I'm not sure why, but Miller only lists that part number in the chart for drive roll sizes and part numbers rather than in the parts manual breakdown (at least on all I can recall). It's part 056-192 and should only run about $15.

[Ps91-rick]

Awesome.. I was able to find that on the parts site and will order it.. Thanks for helping with that!!

[Ps91-rick]

ok.. I was able to get a bunch of little things done on the welder.. all is going well except for one thing.. The replacement "hot" positive cable that runs to the front panel from the contactor (?) (that switches between high/low voltage) -- I've got a new yellow connector for the front-panel end and a brand-new cable (1/0 AWG)..

Unfortunately the 1/0 AWG cable barely fits in the brass connector end before you wrap it with the copper strip OR the wire that is wound around the cable shielding.

Did I get the wrong size cable? The parts manual calls out part #082067 for the cable but I find no reference on the net for that part. The 1/0 AWG cable looks exactly like the old cable size wise..

When I put the same thing together with the 4ga ground cable that I fabbed up it fit perfectly -- if a hare loose before tightening the screws.. thoughts??

[Ps91-rick]

Here's some pics I took earlier -- unrelated to my problem as I forgot to take pictures of that.. oops!

A few of the pics show the new connector crimped & soldered on the high-voltage conductor from the main transformer that was missing. I cleaned it with a wire-wheel really well, crimped it as best I could and then soldered it with a torch which worked like a charm.

The other related pictures are the two high/low voltage taps from the transformer attached to their new front panel connectors.

I did manage to find a picture I took of the AWG 1/0 wire I mentioned above.

[Aeronca41]

Lookin' good!