Operating Instructions and Parts Manual
Troubleshooting Chart - Welder
Symptom
Possible Cause(s)
Corrective Action
Welder runs but | 1. | Inadequate current at electrode | 1. | Check work clamp, cable and connection to work piece. Check |
does not weld |
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| electrode cable and clamp |
| 2. | Poor connections at welder | 2. | Check all welder external connections |
| 3. | Front panel switch set incorrectly | 3. | Set front panel switch to weld |
| 4. | Open, shorted, or incorrect wiring | 4. | Referring to the wiring diagram, clean and reconnect all wiring ★ |
| 5. | Faulty capacitor | 5. | Replace capacitor ★ |
| 6. | Open or shorted field windings | 6. | Test winding resistance, replace field winding if necessary ★ |
| 7. | Open diodes | 7. | Test diodes, replace if necessary ★ |
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Welder gives trickle | 1. | Accidental contact with work piece | 1. | Avoid contact with work piece |
shocks | 2. | Current leakage caused by moist | 2. | Make sure clothing and work area are dry |
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| clothing or work area |
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Arc difficult to strike | 1. | Wrong type of electrode. | 1. | Verify that electrode is for alternating current (AC) |
| 2. | Electrode diameter too large | 2. | Use smaller diameter electrode |
| 3. | Work piece not properly grounded | 3. | Verify proper grounding. (No paint, varnish or corrosion) |
| 4. | Engine speed is too slow | 4. | Adjust engine speed |
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★These diagnostic and repair procedures should be performed by an authorized service center.
Troubleshooting Chart - Welds
Symptom
Bead is intermittently too thin or too thick
Possible Cause(s)
1.Inconsistent travel speed
2.Output amp setting incorrect
Corrective Action
1.Carefully watch and control the width of the molten weld bead
2.Adjust output amp setting or change to smaller diameter electrode
Ragged depressions | 1. | Travel speed too fast | 1. | Watch orange molten weld puddle and control bead width |
at edge of weld | 2. | Arc length too short | 2. | Practice running electrode across workpiece with welder OFF |
| 3. | Output amp setting too high | 3. | Reduce output amp setting |
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Weld bead does | 1. | Inconsistent travel speed | 1. | Decrease and maintain constant travel speed |
not penetrate base | 2. | Output amp setting too low | 2. | Increase output amp setting |
metal | 3. | Electrode diameter too large | 3. | Change to smaller diameter electrode |
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Electrode sticks to | 1. | Arc length short | 1. | Lift electrode to correct arc length as soon as arc is struck |
workpiece | 2. | Amp setting low | 2. | Increase amp setting or change to smaller diameter electrode |
| 3. | Incorrect electrode | 3. | Verify electrode is suitable for 62.5 V open circuit voltage |
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Electrodes sputter | Damp electrodes | Use dry electrodes and store in dry location | ||
and stick |
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