TROUBLESHOOTING | ||
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| Observe all Safety Guidelines detailed throughout this manual |
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PROBLEMS
(SYMPTOMS)
POSSIBLE
CAUSE
RECOMMENDED
COURSE OF ACTION
Output Problems
Wire feed speed consistently oper- | 1. | The jumper lead for normal | 1. | Properly | connect the normal | |
ates at the wrong value. The speed |
| speed/extra torque is connected |
| speed/extra torque jumper. | ||
changes when the wire feed speed |
| improperly. | 2. | Install the proper pinion gear in | ||
knob is adjusted. | 2. | The wrong gear is installed in the |
| the wire drive. | ||
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| wire drive. | 3. | Replace | the motor/gearbox | |
| 3. The brushes on the motor are |
| assembly. |
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| worn. |
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The wire feed speed is fast (maxi- | 1. | The tachometer is connected | 1. | Verify all of the tachometer leads | ||
mum) and there is no change when |
| improperly. |
| are properly connected. | ||
the wire feed speed knob is adjust- | 2. | The tachometer has failed. | 2. | Replace the motor and tachome- | ||
ed. |
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| ter assembly. | ||
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Variable or "hunting" arc. | 1. | Wrong size, worn and/or melted | 1. Replace the contact tip. | |||
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| contact tip. |
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| 2. | Worn work cable or poor work | 2. | Verify all work and electrode con- | ||
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| connection. |
| nections are tight and that the | ||
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| cables are in good condition. | ||
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| Clean/replace as necessary. | ||
| 3. | Wrong polarity. | 3. | Adjust polarity to the recommend- | ||
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| ed procedure. | ||
| 4. | The gas nozzle is extended | 4. | Adjust the gas nozzle and shorten | ||
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| beyond the contact tip or the wire |
| the stickout to 3/8 to 1/2 inches. | ||
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| stickout is too long. |
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| 5. | Poor gas shielding on processes | 5. | Check gas flow and mixture. | ||
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| requiring gas. |
| Remove or block sources of | ||
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| drafts. |
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(Digital display models) | 1. | The | 1. | Place the | ||
When the trigger is pulled, the wire |
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| "OFF" position. | ||
feeds slowly. |
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(Digital display models) | 1. | The preset voltage calibration in | 1. | Use the | ||
The preset voltage does not match |
| the feeder has been selected for a |
| the preset voltage calibration in | ||
the power source voltage. |
| different power source. |
| the feeder to match the power | ||
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| source. |
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Poor arc starts with sticking or | 1. Improper procedures or tech- | 1. See "Gas Metal Arc Welding | ||||
| niques. |
| Guide" | |||
and ropy looking bead. |
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CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
