Models WF2150, WF2154,

 

 

 

WG2160 and WG2164

 

 

 

 

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 lamp goes out

 

 

2. Poor work clamp connection

2. Be sure all connections are secure, and attaching surface

 

 

3. Blown breaker or fuse

is clean

 

 

3. Reduce circuit load, reset breaker or replace fuse

 

 

 

 

 

 

Wire tangles at drive roller

1. Wrong size contact tip

1. Use proper size contact tip

 

 

2. Torch liner clogged or

2. Clean or replace wire liner

 

 

damaged

 

 

 

 

3. Contact tip clogged or

3. Clean or replace contact tip

 

 

damaged

 

 

 

 

4. Drive roller worn

4. Replace

 

 

5. Not enough tension

5. Tighten tension knob

 

 

 

 

 

 

Gun nozzle arcs to work

1. Slag inside gun nozzle

1. Clean slag from gun nozzle

 

surface

2. Insulation ring melted/expired

2. Replace nozzle

 

 

 

 

 

 

Work clamp and/or cable

1. Poor contact

1. Be sure all connections are secure, and attaching surface

 

gets hot

2. Using an extension cord with

is clean

 

 

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 tension knob 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

 

 

 

 

 

 

 

 

Weld pops and sputters

1. Wire speed setting

1. Tune in correct setting (1-5 mild steel; 5-10 aluminum)

 

 

2. Contact tip size too large

2. Replace contact tip

 

 

3. Polarity set incorrectly

3. Reverse polarity

 

 

4. Drive roller slipping

4. Increase tension

 

 

5. Gas bottle empty

5. Replace gas bottle

 

 

 

 

 

Bead is intermittently too

1. 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

1. Increase and maintain travel speed

 

thick

travel speed

2. Reduce output heat setting

 

 

2. Output heat setting too high

 

 

 

 

 

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

4. Use only 100% Argon gas

 

 

(aluminum)

5. Never use an extension cord longer than 20 ft

 

 

5. Extension cord is too long

 

 

6. (Aluminum) Possible oxide

6. Clean surface thoroughly with a stainless steel brush only

 

 

buid-up on surface

 

 

 

 

 

 

 

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-cored wire when not using gas

 

 

4. No or low shielding gas

4. Use gas for MIG process or refill bottle

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