bad cable to machine connection on my maxstar

admin

ive been using my relatively new maxstar 150 lately. i'm running a few inches of weld in each cellblock and don't want to drag the idealarc and an electrician with me. no matter how snug i make the welding lead to machine connection it's working loose. the short come with the machine leads aren't helping because i have them extended and am putting tension on the connection point. it's got the dinse type connector and i'm thinking to change it to a tapered pin or ball point to eliminate the problem. has anyone else with this machine had trouble like this?i.u.o.e. # 15queens, ny and sunny fla
Reply:Not that exact problem but I did just have to replace one of the connectors on the Maxstar150 at work because the ground lead wouldn't tighten up, it would just spin.  I am not exactly sure what happened to it as most of the time the leads stayed in the machine but there were a few times it went on the road and maybe someone hamfisted it.  But thinking back, the connectors on that machine never really did feel like they were tightening up correctly.  You are correct that the short leads that come with it really do suck.
Reply:I haver had any issues with mine. Are the connectors on the leads genuine Dinse? I've heard of import knockoffs not fitting very well in Dinse panel mount connectors, but this was mainly with the bigger ones.As far as changing the connectors, it would probably not work out too well being how they're set up in the panel of the machine. Is yours the stick welding only unit or the lift arc one?Expert Garage Hack....https://www.facebook.com/steven.webber.948
Reply:Not real familiar with the maxstar 150, but I believe tose are the small dinse connecters. My esab uses them and they seem to loosen up. On mine you can't really twist them tight to begin with.  I leave my leads attached since they are short and just tightened them with a pliers. Another option may be to get adapters that let you use the larger dinse or tweco connecters and tighten the adapter down tight.
Reply:Originally Posted by 7A749I haver had any issues with mine. Are the connectors on the leads genuine Dinse? I've heard of import knockoffs not fitting very well in Dinse panel mount connectors, but this was mainly with the bigger ones.As far as changing the connectors, it would probably not work out too well being how they're set up in the panel of the machine. Is yours the stick welding only unit or the lift arc one?
Reply:Longer leads will help a lot. Giving them a tweak with a pair of channel locks as MJD suggested will probably go a long ways towards keeping them tight. I usually put a dab of anti seize on them too. Helps prevent corrosion and dissipates heat.Expert Garage Hack....https://www.facebook.com/steven.webber.948
Reply:Another thing to check is make sure that the entire lead is turning when tightening up.  One of the factory leads on the one I used, the outer rubber covering would start to turn just when the metal was starting to tighten.  If you weren't paying attention you wouldn't notice what was going on.
Reply:Originally Posted by OxfordAnother thing to check is make sure that the entire lead is turning when tightening up.  One of the factory leads on the one I used, the outer rubber covering would start to turn just when the metal was starting to tighten.  If you weren't paying attention you wouldn't notice what was going on.
Reply:I had the exact same problem on my Maxstar 150S. I put a thin copper washer over the Dinse connector so that it goes between the shoulder of the connector and the female socket on the machine. Solved the spinning and loosening problem.The connectors are 25mm Dinse connectors; you may want to try new ones from Lenco and see if they fit better. Then you can make the leads as long as you want.JohnA few weldersA lot of hammersA whole lot of C-clamps
Reply:Originally Posted by Silicon-basedI had the exact same problem on my Maxstar 150S. I put a thin copper washer over the Dinse connector so that it goes between the shoulder of the connector and the female socket on the machine. Solved the spinning and loosening problem.The connectors are 25mm Dinse connectors; you may want to try new ones from Lenco and see if they fit better. Then you can make the leads as long as you want.John
Reply:Originally Posted by Silicon-basedI had the exact same problem on my Maxstar 150S. I put a thin copper washer over the Dinse connector so that it goes between the shoulder of the connector and the female socket on the machine. Solved the spinning and loosening problem.The connectors are 25mm Dinse connectors; you may want to try new ones from Lenco and see if they fit better. Then you can make the leads as long as you want.John