I Bought a Broken Portable Welder - Can I Fix It? | Miller Bluestar 2E Part 1
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- Опубликовано: 7 янв 2023
- I bought this Miller Bluestar 2E portable welder for $100. It doesn't run or weld. Let's see if we can fix it.
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I’ve learned two reasons of why Miller is superior…
1. The manuals and wiring diagrams are available online.
2. They have tech support that will help you troubleshoot and get your machine running again.
I always did the troubleshooting myself, until one day ran out of ideas. I called them up, they told me a couple key things to check, and that helped them lead my down the path to the failed part. They were willing to stay on the line while I ran the machine and poked around with my meter.
That's good to know. I have a nice one that quit working and is all electric
if you have a miller you are going to need all that help because they all burn out and stop working long before the engines ever start to smoke. they are junk
Maybe coz they break all the time and need that info and parts
@@mikecubes1642😂😂😂
I bought a partially disassembled 1993 Lincoln SA250 a couple of years ago. I reassembled it, got it running, and found that it wouldn't weld or make auxiliary power. I called Lincoln, who took my phone number and scheduled a time for a semi retired tech of theirs to call me. I believe his name was Bob Crow. It took him less than fifteen minutes to figure out the problem, a shorted armature. He and the other tech on the line recommended a rewinding service to send it to, as well as a couple of aftermarket sources for parts that Lincoln has obsoleted.
Contrast that with Miller. My employer has a Syncrowave of similar vintage. We sent it to their techs to be repaired. They had it for several months. They eventually sent it back, claiming it was fixed, although it wasn't, and charged several hundred dollars for the service. They also said a pressure switch was obsolete. It isn't. Frankly, Miller fails by comparison.
Lincoln has manuals and literature online. They have also supplied me with diagrams of control boards not found in the manual or general user literature.
I love the diagnostic path you took. For people who are not mechanically inclined, they simply don't understand the satisfaction one gets bringing something mechanical back to life. In this now throw away world, it's nice seeing someone's junk being brought back to life so it can be used for years to come. Well done.
Ditto
I recon we are individually technologically regressing. Things that or fathers fixed on the dining room table, we don't even know how they work.
As for new tech, less and less people actually know how it works and as a society we generally don't care how it works so long as it does.
Your mom’s mechanical
@@flightforensics4523 He's definitely not a carburetor guy, I think a self-professed one, but small engine carburetors are an easy equation and they are almost always in need of TLC on old neglected equipment.
@@BlackCoinCrypto Every 'body' seems to be afraid to get their hands dirty...
College wannabe sophists.
$100?? That's a $600-700 dollar welder here in the UK in that condition. You did well Wes.
Wes, I bought a used Lincoln weldandpower diesel generator for $35, did some work to it and sold it for $600. It was put on a trailer.
You were never nearly out of options, there's nothing you can't handle. Great video as always, keep them coming
Holy crap……Powcon welders!!!! Haven’t seen one of those since my welding days in the Navy. Still remember having to throw that heavy thing on my shoulder with the leads and carry it down ladderwells to job sites on the ship. 😂 Our welding current was 440 volts
A friend of mine had a Century MIG welder that he had had multiple issues with since he bought it, and Century got so tired of dealing with him that they just sent him a new machine. He asked me if I wanted it, I told him sure. Turned out that the problem was just the trigger switch in the handpiece. Free welder for me -- he had a new handpiece that he had bought, and never put on, because he got tired of troubleshooting before he got to it. But it was in the box of stuff that came with it.
I love videos like this!
Scores! Noice👍🏻
Why should I get up early, go outside in to the cold, and do my own work around here...when I can just Watch Wes Work! Thanks for the vids! 👍👍
We ran powcon 400amp welders at the trailer shop years ago and they were great welders. 100% co2 and spray arced everything
Thought I was on the Mustie1 channel for a minute! Awesome job diagnosing the issues. Looking forward to another year of wrenching and dry humor!
Yep, confused me too,crusty junk, old engines, carb parts in an ultrasonic cleaner!
Yeah, but mustie probably can’t fix the generator side like that
I had every confidence in you. Right up my street this one. Love taking dead junk and getting to the bottom of it. Looking forward to part two. Have a great 2023 all of you.
I look for your video every weekend. Looking forward to watching this. Thanks for taking the time to share your work. I hope you and your family have a great 2023.
While Mustie is at the museum, Wes steps in to save the day 👍
Wes, I'm 67, and I'm really in awe that you have so much knowledge and persistence, and are talented to repair things at your young age. Stay healthy and thanks for sharing!
Did Max certify these welders as critter free? 👅🐾🐾
It's easy for him, relatively speaking, in this day and age because of the information superhighway and the free-flow of information from the professional repairmen willing to share their knowledge and they too are on the internet. Wes is a rarity in a vastly shrinking population of wise men and we all know it. Conversely, every man woman and child has a handheld mini computer {smart phone} in their hands, staring at them intently but what do they use them for? Video entertainment and other low IQ dalliances....
@@Hjerte_Verke I tell people I'm too dumb to use a smart phone. But, that really ain't the issue. Being or becoming addicted to technology is just AS dangerous AND destructive as ANY drug! Just ask someone who's walked out into a busy street, or into a fountain whilst their head was locked onto that tiny screen. "I tell you now." "You believe me later." 😜
@@AmosBHaven HUMPH, technology has just given the easily distractable(I am one of these) ANOTHER way to f'up
Don't blame the tech
BTW, the smartphones are a bit too much for me too...
@@Hjerte_Verke It's easy to find a lot of info on the internet compared to the old days for sure, but you gotta give Wes some credit here. I've been wrenching on everything from heavy equipment and cars/trucks to electronics for 30 years now with access to the same info as him for most of that, and I don't hold a candle to Wes. The man is very knowledgeable and very intelligent.
Love the troubleshooting Wess, I've been in the industrial maintenance for over 43 years now and troubleshooting has always been the greatest reward.
It seems a majority of comments applaud your diagnostic skills which are right on center stage and amazing, then the humor which complements the diagnostics, but I really appreciate when you simplify an explanation for why you are doing a particular task. I'm looking forward to binge watching your videos. "Locked into full Kack"😂 Thanks!
Nice little machines. Maintenance item: check out the armature mounts for cracks etc. Had one break and dropped armature against field. Found others cracked. Luckily caught it in time, no major harm. Good day to you, great content!
I really enjoy this type of investigative troubleshooting, especially when it's spanning multiple "disciplines" (engine & electrical). Looking forward to part 2. :)
👍 totally agree
Walbro carbs are pretty good. I have a small engine shop and repair lots of carbs. If you can't get the emulsion tube out, you can get small brushes that will go inside of it and clean the tube orafaces. Nice welder, hope it will work for you. Thanks
Thank you VERY MUCH for taking the time for the shop lesson👍👍👍
The ability to "think on your feet"- invaluable.
I didn't know it'd be a James Condon video on generator repair, but it shows off how great your diag skills really are. Glad you found most of the problems and parts are available. Happy New Year!
Love seeing videos of older machines and the explanations about how it generates its magnetic fields. Great video and explanations!
Your insistence and stubbornness regarding problems is VERY relatable for me and is exactly what I love about your channel.
I also love your honest sense of humor and use of sarcasm. :D
Find myself sifting through videos by you sleeperdude and vicegripgarage daily. Very entertaining and informative. Thank you
If it works, that powcon is a real gem, My uncle had one for 30 some years in his machine shop. It predates the miller xmt 300/350, but is basically the equivalent, one of the first inverter light weight welders to hit the market, a very high end machine when new
I love the troubleshooting, I am a retired engineer and used to be the goto guy when others were stumped , I like the way you always check the drawings and also challenge what you see and also use the does this make any sense test!
Miller bought out PowCon welders simply for the inverter design. The first Miller XMT's were blue PowCons, same case and everything. They were really well made and lasted forever.
🧐🤨🤓👍🏻👌🏻😎
Miller bought Powcon in the mid 1990s to gain control of Powcon's inverter power supply patents. I own a Miller XMT-300 machine; it's just a blue Powcon. A year of two later Miller "Millerized" the Powcon designs, changing the fiberglass case into a metal case, it was called a XMT-304. These machine were light in weight and had great stable arc characteristics.
Good the see ya Wes! I just want to let you know that I subscribe to 493 RUclips channels. Every day when I get on my laptop I check for a new vid from YOU. Before you say "dude, get a life", I'm disabled and not capable of doing much. I ALWAYS appreciate your content. Thank You!
“It’s a little rough around the edges - should fit in fine around here.” 😂😂
I've seen lots of PowCon welders in the navy. The ones we use on submarines are a smaller version of what you have that are set up for TIG. Good work getting that Miller brought back to life.
Some 30 years ago, I worked at a bio-mass steam turbine plant...small, 35 megawatts...When it was time to change out the boiler super heat tubes (2' Chro-moly) we used a couple pow-cons with scratch start TIG...they worked pretty well.
Awesome. Now we wait for part 2. Love to see "machines" being brought back to life when there's still life and use in it.
Top tip from Wes, when buying a load of equipment from an auction, make sure you include a work bench 😀 😉 👍.
Great job 👏.
Thanks for sharing.
"Now that we've spilled gas everywhere, lets try and weld something" lol
You've convinced me that I need an ultrasonic cleaner. You can get replacement carbs for that on eBay. Cheap Chinese carbs, but they work. Talk to Lincoln, if they don't have a part you need, they can point you towards someone who does.
Excellent work figuring it out!
That's a nice handy little welder to have around for for field repairs. Awesome job on the diagnostics Wes, you make it all look simple.
Not only welding, but also single phase for all kinds of tools, all in a small and easily portable footprint, it's really a versatile machine to have
72 year old retired generator guy here - I used to have that exact welder about 1985 or so - the system you were trying to describe that gets the generator going is called the field flash circuit - be sure and read your book on how to adjust your ac voltage 132 is pretty high - try to not run too much above 124 or so - when you run that thing make sure and put a leash on it - that one lunger will walk right out of the back if your pickup if your not watching... good job. - I picked up a 400 amp Miller pipeliner the other day that would not weld - 15$ later and a new diode I was in business - if I was you I'd put some new main brushes in it and clean up the slip rings - that reostat is a common failure - also work that range switch back and forth - it has wiping contacts but they do need cleaned by working the switch..
I just helped my dad get one of these running. What a nightmare to find parts for.
So you bought the last capacitor that he needed 😀
It was a welcome change to see you poking around with something that has no steering wheel.
Clearly Max was giving you some insight on the welder’s problems. I think I heard him say something about rodents… 🤣🤣🤣
Keep up the good work
Really enjoyed this video Wes. Who among us hasn't had a piece of equipment we needed to trouble shoot like this and didn't know how. Looking forward to the other gems you bought and how you get them going and useful again. Thanks for taking the time to share with us. Deb
A new carburetor for that engine on Amazon is about $15. I bought one for a 1984 Honda 125, bolted it on and it worked great.
It’s not always necessary to replace the carb, but when the carburetor is getting in the way of the “real work”, it’s a good option to consider.
Your tenacity and improvisation skills seems to know no bounds. I am impressed with your skills, talents and knowledge with every video..
Thanks for sharing your adventures!!!
I have a Powcon 300 ST. Tig and stick. Great machines! In fact the US Navy used them on their ships. It can run on three phase or single phase depending on how the jumpers are set up inside. However, you have to de-rate it by 1/3. Unfortunately, Powcon has been out of business for decades, but manuals can still be found online. Powcon was the first to market with these inverter welders, however instead of cheaper IGBT technology that other manufacturers went with, Powcon used SCR’s which made the machines much more expensive, however they were very robust and failures were rare and easily fixed.
Hey Wes, just to let you know you can make a three phase converter fairly easily. Look up a rotary 3 phase converter. It will take some work on your end, but I built one myself my wife's grandfather built one for his shop and my father-in-law built one as well. If you can trace down problems in the electrical system of a car, you can build a three phase converter. Also if you need capacitors check any place that sells electric motors ie poultry supplies pig supplies etc. Or you can check any HVAC supply house, they will most likely have any capacitors that you need
Rotary 3 phase converters have been pretty much obsolete since the advent of cheap and reliable VFDs
@@kenney4043 Yes, but how dirty is the output on a VFD
@@charlesangell_bulmtl depends on the VFD unit. Can be considerably cleaner than a rotary phase converter depending on what your local power company supplies etc. I run a rotary in my shop but have a couple smaller VFDs for smaller things.
Fun fact! I used to work at Miller.. worked at 3phase products and also in the engine drive shop..Great company to work for and things are done to perfection or as close too as possible..got let go in 2008 during the economy crash.. I've wound many 3 phase coils and various other rectifiers and coils for different machines.
Wes.. you know you are quite experienced in your age.. I’m always impressed about that knowledge in that head of yours.. good job figuring that out. Getting something that someone already F with is always a crap shoot.
that's a great find right there,those 2E machines are good little machines, and will last a lifetime with a little maintenance....excellent job at diagnosing the problems as you always do and bringing it back to life
Looking forward to part two of the welder repair. It is great to watch a technician going through the diagnostic procedure and explaining how it is supposed to work. Wishing you the best New Year ever.
Love when sparky sparky comes out of the end of an electrode. Well done figuring out the problem.
That devious laugh of victory is what keeps me coming back for more, but I will say that the supervisor/quality control pup is also right up there with the mass knowledge that you learn or brush up your skills watching Wes fix stuff correctly and safety instead of the hackmanship that is a huge part of the American fix it all mechanic today. Good evening to you Wes!
Excellent electrical diagnosis, Wes. One thing at a time, starting from the beginning. I would expect the rheostat and resistor are your most expensive parts. The pulse fuel pump is rather common, and high-voltage diodes and rectifier bridges aren't too expensive, either. Speaking of which, you might throw another ten dollars at that bridge rectifier. Could save you a lot of future headaches.
I agree on the replacement bridge. Too much bad stuff has happened at that wiring junction. The 10A diode he has will work fine (assuming it is 1KV), and it will be physically more rugged than a 3A or 5A diode. The cap is also a 10 buck item. Most likely that rheostat is going to be 50 or 100 bucks or more, but everything else should be cheap.
Depending on the vintage of the machine, Tecumseh used three different ignition systems. Early versions had points. I'd prefer the points version...for reasons that will become clear shortly. The other two ignitions were electronic, but one was a CDI. The latter two have zero parts support. The CDI version in particular has a second set of windings, similar to the alternator, that are required for it to function. If either one fails, it doesn't run anymore. I have one of the later CDI versions, and the ignition quit on me a while back. There are a couple of aftermarket solutions that can be used, but they're not cheap.
The shot you included at the end.. The lighting is awesome :)
Brilliant to recover a fundamentally sound machine! Should be a solid welder too, there's always something nice and organic about welding against real inertia!
Your knowledge about everything still amazes me. That's why I watch.
We have the tools, we have the talent. It's Miller time!
You can absolutely get parts/rebuild kits for them all over the place. you might have already tried this but sometimes you cant pull the emulsion tube from the bowl side you have to stick something in through the intake side and push it down through there. Not sure if that is the case with that exact carb but worth a look if it gives you trouble down the line.
Agreed, the emulsion tubes are often just retained by the main jet, but they can be pretty tight to get out.
I was really waiting the whole video for Wes to say, "Well, I've summoned my inner Mustie1 and the carburetor is clean and engine is running smooth".
I like your calm demeanor while troubleshooting problems, and your in depth explanations of exactly what you are attempting and why. You do a great job Sir, and I enjoy watching no matter what you are tackling today. Keep up the good work! Ill be watching!
Can't wait for part 2! You're amazing at troubleshooting Wes!
Great video Wes, I love you don’t just focus on big equipment. It’s fun to watch your process going through the steps to figure it out!
I'm so glad you are able to make video's as well as you have been doing. I'm also glad that you use knee protection when kneeling on concrete. Trust me when I tell you that the concrete and knee kneeling will cause issues
Those PowCons are awesome. It is what we used in the Navy. I was a turdchaser so I had to hump Powcons every day. That and an LTec plasma cutter with 440 cables 110 cords, and air hoses. You had to make sure the gang boxes of the 440 leads were on your back or they hit you in the nuts while carrying. Those Powcons took a beating and just wouldn't quit. Had to do a deck drain one day. There is an adaptor you can attach to the Powcons so you can do aluminum MIG. Perfect 360 weld.
Damn!!!! I wondered what happened to my PowCon!!! I love seeing that Massey in the background! Heavy equipment video coming soon to a RUclips channel near us?!?!?! Great video Wes! Happy New Year!
I'm hoping that Ford/New Holland 'hoe makes an appearance!
Great video Wes, like when you detour from the normal automotive stuff! Hope you and the family find health and prosperity for the new year!
Well done and thanks for bringing us along for the ride 😀
My cousin had that same welder. It was a workhorse. He made a lot of money with it doing repair work. Paid for itself in no time. Definitely work fixing.
Great project and great diagnosis. Smart sliding that lead down on that resistor I had forgotten you could do that. 👍🏼
Great episode,always like your diagnostics...really want to see part 2,great welder.....that plasma cutter looks well handy.
I have a Miller 2E that I bought new in 1987. Has been faithful. Had the carb to develope a tiny pin hole in the round 3/8" round alum circle near the idle screw two yrs ago...Pluged that. Had to replace the org. starter, then I bought a "spare" new one...cause they are not making them anymore. Am real careful to change the oil frequently, what with no oil filter.
I learned a lot from your vid, Thank you.
This is what it's all about: fixing junk that doesn't matter. I have a project vehicle that should've been done before the new year and yet, what am I thinking about? The ancient, *MADE IN ENGLAND-LAND* vise that I just picked up from an old-timer. I'd much rather be fixing that up, but it's gotta wait--annoying. Great video Wes, just proves that old welders are like old Welders: a bit of jabbing with a pointy stick and some magic juice and just watch us go.
Love the outro with the Miller basked in a Halo of moonlight. Very dramatic.
POW con was if I remember correctly was a military only type of company. They worked and did the job but nothing to write home about
Happy New Year Wes! Looking forward to this years vids!
Ooooh a cliff hanger episode! Will the Blue Star return to its glory and become the belle of the ball in Wes’ ever growing empire? Or will she chooch her last and take the electricity out of the room? In all seriousness great diag and fix.
I’m liking the Mustie1 vibe this video has. Love the bring back from the dead type of videos sometimes. Always great work to see Wes.
Good to see you Sir, Happy New Year All
We had a couple of powcons at trade school, great units I preferred those over the miller xmt's most of the lab had. Passed my structural cert on them, nice smooth arcs
Just when I think I'm decent at diagnosing small engines, I watch one of Wes's videos and realize how much there is to learn.
Watch Mustie1, he brings junk back from the dead too. 👍🏻
Wes lots of excitation going on. Sounds like a Beach Boys song. The fact is if Wes and Max can’t get it working no one can!
I love the content and the new format style. Keep it coming. Long time subscriber.
Sunday giggles with Wes!
Love seeing ya start off the year in the best way possible.
Everything stops for a Wes video thank you
Stay tuned for the shocking conclusion :D Just replace that fuel pump with a standard round pulse pump. rebuild kits have long been nla from techumseh I have done the conversion on several of my old tractors that use the techumseh motors. Standard briggs and stratton round fuel pump from any modern twin or single works perfectly 520-441 stens part number. just find a convenient spot to mount it and run your pulse and fuel lines in.
Dear Mr. Wes.
Happy new year to you, your family/friends and dog Max. 2) 👍👌👏 Very "weld" done again (video and work). This sturdy, heavy, old style, reliable Miller mobile welder station is definitely a nice thing to have. I really, really hope that you will also fix all the other equipment that you showed us. I simply love videos like this.
Thanks a lot for making teaching explaining recording editing uploading and sharing.
Best regards, luck and health in particular.
Thanks, Wes. Really enjoyable to watch Wes diagnose!
Wes you sure can figure it out! Thanks for taking the time to share.
Super interesting. Better than all cars all the time.
Happy New Year with great info on how to trouble shoot a old welder. Love Max reading the schematic wiring diagram due to no mice hiding in welder. 😊
The MANIACAL LAUGHTER of UNDERSTANDING!!!!
Did you believe you were without a "Video Quality Repair" after it started and ran, until "Now we're kicking that dead horse we needed for a good video!" when it wouldn't produce decent welds. Good diagnostics with even better video of the process with the best part......
The MANIACAL LAUGHTER of UNDERSTANDING!!!!
Thanks for sharing this gem with us - clear, concise and simple explanation at every stage - always a pleasure to watch.
Enjoyed the video Wes
Happy New Year Wes to you and your family!
Always find your videos entertaining, so keep em coming. Anybody that has the patience to work on modern autos can fix anything.
Way to go! Nice to see this sorted out - just needed maintenance!
Very nice troubleshooting as usually Wes.
Happy 2023.
You can always get a VFD to run that plasma cutter if you can't swap it to single phase.
Tim is 100% as this is the simplest (and probably cheapest) way to go.
I doubt it, many 3 phase welders are really only single phase, but use the higher voltage between phases rather than the lower voltage from phase to neutral. For example in Australia we have 240 V single phase but 415 on 3 phase. Higher end welders will often be genuine 3 phase, to get smoother DC after rectification, but even here a VFD will be of limited use because the voltages between phases will be the same as the single phase supply, so in the U.S. even on a 220/240 V circuit the 3 phase voltage will be the same as the single phase supply.
@Rope Tangler idk what you're talking about because in the US, you can get 120/208 3ph, which has less voltage per phase than 120/240. And you can also have 277/480 3ph which is found in commerical and industrial settings. But even if a vfd doesn't work, which it probably will. He can get a rotary phase converter.
@@timhufnagel7462 you need sufficient voltage and the ability to supply sufficient current to make it work. If in the U.S. you put 120V, single phase into a VFD to get 3 phase you do not normally get 3 phase at 208 volts between phases, but you get 3 phase with 120 volts between phases. Much the same situation with a RPC, while it is possible to make a RPC with higher voltage output between phases than the incoming single phase supply, that is not the way most are configured.
How to test your marriage 101. Bring home a truck full of junk from an auction.
It's nice to see a "real" trouble shooter" on top of his game. Awesome job! Too many parts changers disguised as mechanics today.
Good job getting that running, thanks for the video Wes!
Hey Wes, nice to see some alt content fella. Its too easy to forget your not just a talented mechanic :-) And max is a good boy, did he step on something again though.
I don’t see any junk there.
Great one - another milestone in forensic repair. Cameo by pup was the icing on the cake 👍🏻
That was a fun change of pace. Keep up the good content.