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[MinnesotaDave]

First thing I would check are the contacts on the range selector.

Mine will give me no power in the midrange sometimes, if I just move it back and forth a couple times it will make a connection and work.

I've not taken it apart to find out why - but I suspect my contacts are...

[MinnesotaDave]

Is an engine drive air compressor possible for you?

[MinnesotaDave]

Here is a manual for it:

http://www.millerwelds.com/om/o1545j_mil.pdf

[MinnesotaDave]

Often on my machine if I touch the tungsten to the work piece just before I weld, then lift it slightly before hitting the pedal, it works.

Don't know why it works, but several guys have told me they do the same.

Here is a tech manual I have saved in a drop box:
http...

[MinnesotaDave]

When I asked miller tech, they told me the maxstar will run off any normal 5000 watt generator. It ran great off my old Generac 5000/6250 genny, transformer based mig welders did not.

The maxstar is power factor corrected (PFC) and does not require a low THD (total harmonic distortion)...

[MinnesotaDave]

I've been using oxy/propane since the 90's and have never regretted making the change

A person can't weld with propane, but I've got mig, tig, stick so it's of no concern....

[MinnesotaDave]

You may want to look into using oxy/propane - that's what I use for cutting and heating.

Cheaper and no withdraw rate or overpressure issues.

[MinnesotaDave]

If it looks like mine (pic attached), it's actually a Miller 330 abp and uses the same foot control.

I see them on ebay on occasion....

[MinnesotaDave]

15 amp circuit will still run that welder - just not at the higher settings (pops the breaker).

I've used two migs on generators - 5000 watts (continuous output, not surge). Didn't weld very well - need to go bigger than that.

The larger the generator, the better the mig will...

[MinnesotaDave]

I agree, you probably popped a diode - I've had it happen and it can put your machine on full load that's why your breaker tripped.

Test to find the bad one - cheapest I found them was on ebay from a place that sells them for DIY wind power.

[MinnesotaDave]

In my opinion, just use the door chart and weld happy until you have a need for measuring WFS

The door charts are generally very close - try it and see how it welds - adjust from there. On my millermatic 210 I generally have to turn down the wire speed slightly on thin steel due to the...

[MinnesotaDave]

Raferguson - you may have to define "extreme difference" - my flowmeters have a static pressure (by design) of 50psi when there is no flow.

[MinnesotaDave]

Sometimes a new guy will lay a weld bad enough that even the machine will gasp slack jawed!

The sudden intake pops the needle over the pin......

[MinnesotaDave]

I use a wood blade on my air die grinder for aluminum.
(this one is from a "jam saw" or "toe kick" saw - smallest I could find)

I drill it out to fit a reducer bushing that I have and chuck it up.
(yes, it's dangerous - so are chain saws...lol)
...

[MinnesotaDave]

Yep, unscrew or pop off that plastic cover and move the needle over the pin.

Adjust your regulator to the flow you want and you're all set