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Welder generator burning up tool switches
I bought a used portable Miller welder generator with a 2 cylinder Onan engine.
It has two settings and outlets for 110VAC. When at an idle it produces 110 but not a lot amps. The other outlet requires flipping a toggle swith to "power while welding" which revs up the engine and produces a lot of power.
I went to use my 6" bench grinder. The grinder was spinning fairly slow at engine idle and slowed even more when I reid to gring=d a small bolt, so I kicked the gen. up to more power---all of a sudden I heard a high pitched "screaming" sound inside the grinder switch and the grinder would not spin---then the switch started smoking. And now it won't run at all.
This high-pitched screaming sound also happens while welding---comes from the actual arc being made.
So I tried a belt/disc sander. Same thing--noise, smoke not working any more.
Note that my other tools like a 9" angle grinder, 1/2" drill, 4" angle grinder and sawz-all all work fine.
Could it be the type of motors (brushless?)? Both the bench grinder and the sander are made by Crapsman...I mean, Craftsman.
Anyone have any ideas--other than a "loose nut" (or as Kenny says a "lose nut" behind the switches?
(In case anyone cares or remembers, I had a 5000 watt welder generator that stopped working. Would have cost more to fix it than replace it with new. I put it on Detroit-area Craigslist for $200 and a guy in Mexico found it on-line. He sent his brother who was here to buy it and ship it to him.)
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Welder generator burning up tool switches
Jeff, first off, I do recall being told you should always start inductive loads (such as motors) with the genset putting out full power, then if it has automatic load sensing let it come back down on it's own.
It could be that at idle it doesn't really put out 110 volts, start it up and at idle put a meter on it and check.
I do know that once you let the smoke out of things it's not easy to make the situation right. 
Best of luck.
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Welder generator burning up tool switches
In my tool collection, those that you described as working with the genset have two prong connectors - some not even polarized. Of those you say burned up, mine have three prong connectors. So I'm going to suggest two things; (a) ground the genset, and (b) verify the line/neutral polarity
//greg//
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Welder generator burning up tool switches
The fact that the motor was described as "spinning fairly slow at engine idle and slowed even more when I tried to grind a small bolt....." tells me that it was not getting the full voltage it requires.
Bear in mind, as voltage drops, current increases proportionately, under load it would be even more so.
It seems the switch was the weak link in the chain, and it failed.
It may just be that the other tools are able to handle an under voltage/over current situation better than the other two tools were.
Best of luck.
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