Shielded Metal Arc Welder
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Troubleshooting Chart - Welder
Symptom | Possible Cause(s) | Corrective Action | ||
Welder does not hum when | 1 | . No power at receptacle | 1 | . Check circuit fuse or circuit breaker |
turned on | 2 | . Broken or damaged power | 2 | . Power cable requires service |
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Welder hums but does not | 1 | . Inadequate current at electrode | 1 | . Check work clamp, cable and connection to work piece. |
weld |
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| Check electrode cable and clamp |
| 2 | . Poor connections at welder | 2 | . Check all welder external connections |
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Welder gives trickle shocks | 1 | . Accidental contact with work | 1 | . Avoid contact with work piece |
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| piece | 2 | . Make sure clothing and work area are dry |
| 2 | . Current leakage caused by | ||
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| moist clothing or work area |
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Welder overheats - blows | 1 | . Use of extension cord | 1 | . If possible, relocate welder to avoid use of extension cord. If |
fuses, trips circuit breaker |
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| relocation of welder is not possible, use thicker (lower gauge |
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| number) extension cord |
| 2 | . Electrode diameter too large | 2 | . Use smaller diameter electrode |
| 3. Overloaded circuit | 3. Welder requires a dedicated 115V circuit | ||
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Arc difficult to strike | 1 | . Wrong type of electrode | 1 | . Verify that electrode is for alternating current (AC) use |
| 2 | . Electrode diameter too large | 2 | . Use smaller diameter electrode |
| 3 | . Work piece not properly | 3 | . Verify proper grounding. (No paint, varnish or corrosion) |
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| grounded |
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| 4 | . Heavy loads making power line | 4 | . Run welder on dedicated 115V circuit |
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| voltage low |
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Troubleshooting Chart - Welds
Symptom | Possible Cause(s) | Corrective Action | ||
Bead is intermittently too | 1 | . Inconsistent travel speed | 1 | . Carefully watch and control the width of the molten weld |
thin or too thick |
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| bead |
| 2 | . Output amp setting incorrect | 2 | . Adjust output amp setting or change to smaller diameter |
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| electrode |
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Ragged depressions at edge | 1 | . Travel speed too fast | 1 | . Watch orange molten weld puddle and control bead width |
of weld | 2 | . Arc length too short | 2 | . Practice running electrode across workpiece with welder |
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| OFF |
| 3 | . Output amp setting too high | 3 | . Reduce output amp setting |
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Weld bead does not | 1 | . Inconsistent travel speed | 1 | . Decrease and maintain constant travel speed |
penetrate workpiece | 2 | . Output amp setting too low | 2 | . Increase output amp setting or change to smaller diameter |
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| electrode |
| 3 | . Electrode diameter too large | 3 | . Recommend either 1/16 in. or 5/64 in. diameter electrodes |
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Electrode sticks to work | 1 | . Arc length short | 1 | . Lift electrode to correct arc length as soon as arc is struck |
piece | 2 | . Amp setting low | 2 | . Increase amp setting or change to smaller diameter |
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| electrode |
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Electrodes sputter and stick | Damp electrodes | Use dry electrodes and store in dry location | ||
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