Lincoln AC 225 setting not working

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I recently purchased a Lincoln AC 225 welder and all of a sudden the 90 amp setting has stopped work.  I opened the thing up and found that the wire from the 90 amp setting had the insulation peeling and the wire was really brittle and had broken.  Is this fixable?  I was going to get a new piece of wire and try to solder onto the 3-4 inch piece still attached to the transformer.  I've searched all over the internet trying to find where someone else has had this issue but I have not.  Thanks for any input.
Reply:If you purchased new, it is under warranty.  If not, talk to a welding repair shop.  IMO, the worst that can happen is your repair won't hold, and you'll have to take it in.
Reply:Thanks for the reply.  I suppose that I will just get a short piece of wire the same size and solder it in there.  If it holds it holds.
Reply:Use high temp solder. No reason it shouldn't hold. The switches are soldered after all. My bud soldered in a complete rotary switch on his with no problems.
Reply:In addition the the repair of the overheated section of wire it is important to determine why it overheated in the first place and correct that cause of failure.  The burned insulation and wire are the symptoms, not necessarily the cause.I am not familiar with the internals of that welder, so can't provide any specific recommendations.  However, assuming that the burned wire was original and, therefore, presumably properly engineered for the current it would carry, perhaps a nearby bolted or crimped connection was loose or corroded.Is it possible that you or a prior owner exceeded the rated duty cycle of the machine?awright
Reply:If it were me I would go to my local electrical supply and pick up 2 copper wire clamps they look like cable clamps but are made of copper. They are for connecting heavy wire together without soldiering. They come in all different sizes from 14 gauge to wire the size of your thumb. I would try to find out why the wire separated as it may be a more serious problem. With the clamps you won't have to worry about the soldier melting and much easier to fix.Good luck,
Reply:The selector is dirty or corrded. Had it happen before solder in new wire and clean selector contacks.I think switch is self cleaning until it seataround. Welding reps say dust is 1 welder killer.