TROUBLESHOOTING
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| TROUBLE |
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| CAUSE |
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| WHAT TO DO |
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| A. Machine fails to hold the “heat” |
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| 1. | Rough or dirty commutator. |
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| 1. | Commutator should be turned |
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| consistently. |
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| or cleaned. |
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| 2. | Brushes may be worn down to |
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| 2. | Replace brushes. |
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| limit. |
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| 3. | Field circuit may have variable |
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| 3. | Check field current with ammeter |
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| resistance connection or inter- |
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| to discover varying current. This |
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| mittent open circuit due to loose |
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| applies to both the main genera- |
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| connection or broken wire. |
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| tor & the exciter. |
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| 4. | Electrode lead or work lead con- |
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| 4. | Tighten all connections. |
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| nection may be poor. |
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| 5. | Wrong grade of brushes may |
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| 5. | Use Lincoln brushes. |
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| have been installed on genera- |
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| tor. |
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| 6. | Field rheostat may be making |
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| 6. | Inspect & clean the rheostat. |
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| poor contact and overheating. |
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| B. Welder starts but fails to gener- |
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| 1. | Generator or exciter brushes |
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| 1. | Be sure that all brushes bear on |
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| ate current. |
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| may be loose or missing. |
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| the commutator and have proper |
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| spring tension. |
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| 2. | Exciter may not be operating. |
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| 2. | Check exciter output voltage |
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| with voltmeter or lamp. |
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| 3. | Field circuit of generator or |
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| 3. | Check for open circuits in rheo- |
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| exciter may be open. |
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| stat, field leads and field coils. |
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| Check rectifier bridge. |
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| 4. | Exciter may have lost excitation. |
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| 4. | Flash fields. (1) |
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| 5. | Series field and armature circuit |
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| 5. | Check circuit with ringer or volt- |
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| may be |
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| meter. |
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| C. Welding arc is loud and spat- |
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| 1. | Current setting may be too high. |
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| 1. | Check setting and current output |
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| ters excessively. |
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| with ammeter. |
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| 2. | Polarity may be wrong. |
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| 2. | Check polarity. Try reversing |
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| polarity or try an electrode of the |
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| opposite polarity. |
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(1)See FLASHING THE FIELDS on following page.
– 18 –