Campbell Hausfeld WG4000 For Information About This Product, Call, Troubleshooting Chart Welder

For Information About This Product, Call 1-800-746-5641

Troubleshooting Chart - Welder

	Symptom	Possible Cause(s)	Corrective Action
No output		1. Duty cycle exceeded	1. Allow welder to cool until ON/OFF Switch lamp goes out
		2. Poor work clamp connection	2. Be sure all connections are secure, and attaching surface is
			clean
		3. Defective power switch	3. Replace switch
		4. Blown breaker or fuse	4. Reduce circuit load, reset breaker or replace fuse
Wire tangles at drive roller		1. Wrong size gun tip	1. Use proper size gun tip
		2. Gun liner clogged or	2. Clean or replace gun liner
		damaged	3. Clean or replace gun tip
		3. Gun tip clogged or damaged
		4. Feed roller worn	4. Replace
		5. Not enough tension	5. Tighten tensioning screw
Gun nozzle arcs to work		Slag inside gun nozzle	Clean slag from gun nozzle
surface
Work clamp and/or cable		1. Poor contact	1. Be sure all connections are secure, and attaching surface is
gets hot			clean
		2. Using an extension cord with	2. Never use an extension cord longer than 20 ft
		excessive length
Wire does not feed		1. Wire jammed	1. Reload wire
		2. Out of wire	2. Replace wire spool
		3. Not enough tension	3. Tighten tensioning screws if wire is slipping
		4. Wire liner worn	4. Replace liner
		5. Wire disconnected internally	5. Call 1-800-746-5641 for assistance
		6. Contact tip clogged	6. Replace contact tip
(Aluminum) Wire burns back		1. Wire speed too slow	1. Run speed in 7 - 10 range
into tip or (aluminum) metal		2. Travel speed too slow or heat	2. Increase the travel speed or reduce heat settings
bubbles or burns through		is too high
		Troubleshooting Chart - Welds
	Symptom	Possible Cause(s)		Corrective Action
Bead is intermittently too		1. Fast and/or inconsistent travel speed		1. Decrease and maintain constant travel speed
thin		2. Output heat setting too low		2. Increase output heat setting
Bead is intermittently too		1. Slow and/or inconsistent travel speed		1. Increase and maintain travel speed
thick		2. Output heat setting too high		2. Reduce output heat setting
Ragged depressions at		1. Travel speed too fast		1. Decrease travel speed
edge of weld		2. Wire speed too fast		2. Decrease wire speed
		3. Output heat setting too high		3. Reduce output heat setting
Weld bead does not		1. Inconsistent travel speed		1. Decrease and maintain constant travel speed
penetrate base metal		2. Output heat setting too low		2. Increase output heat setting
		3. No or low shielding gas		3. Use gas for MIG process or refill bottle
		4. Wrong shielding gas (aluminum)		4. Use only 100% Argon gas
		5. Extension cord is too long		5. Never use an extension cord longer than 20 ft
		6. (Aluminum) Possible oxide build-up on		6. Clean surface thoroughly with a stainless steel
		surface		brush only
Wire sputters and sticks		1. Damp wire		1. Use dry wire and store in dry location
		2. Wire speed too fast		2. Reduce wire speed
		3. Wrong type of wire		3. Use flux core wire when not using gas
		4. No or low shielding gas		4. Use gas for MIG process or refill bottle

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