I know this is not a welder forum, but I know a few run this machine. Has anyone ever had the main power switch fail? Mine has been going bad since about a year after I started using the machine heavily.
I finally had a chance to take it apart. I was going to just buy a new switch, but that would go against my better judgement So, I figured I would investigate a bit more.
I drilled the rivets apart on the switch and separated it. Well, as I expected, the contacts were shot (melted, severely pitted, etc). Ironically, only one set of the 220 contacts (double throw switch), the other leg was perfect
So, I went to Home depot and bought some 8-32 solid brass screws. I drilled out the old contacts, cut the brass screws to leave about 2mm of threads and peened them onto the contactors. I ground the heads flat to match the stock contactor width and re-tensioned the springs below. Then used some long 6-32 screws to hold the switch back together.
Works wonderfully, but odd that it failed to begin with.
I guess some pics, might have helped, but I was in motion..