5-2. Troubleshooting
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| Problem |
| Solution | |
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Unit is completely inoperative. |
| Check continuity of Power switch S1, and replace if necessary. | ||
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| Reset circuit breaker CB1 if open. |
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| Check input power source. See welding power source Technical Manual. |
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Wire does not feed, unit completely inop- |
| Turn Power switch On. | ||
erative. |
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| Check 14−pin receptacle connections. | |||
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| Check input power or the CB |
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Wire does not feed. |
| Check gun trigger connection at wire feeder. Check gun trigger leads and trigger switch. See gun Owner’s | ||
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| Manual. |
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| Have Factory Authorized Service Agent check drive motor and control board PC1. |
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Wire feeds erratically. |
| Readjust hub tension and drive roll pressure. | ||
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| Use correct size drive roll (see Parts List). |
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| Clean or replace dirty or worn drive roll. |
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| Remove weld spatter around nozzle opening. |
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| Replace contact tip or liner. See gun Owner’s Manual. |
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| Have Factory Authorized Service Agent check drive motor and control board PC1. |
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Wire feeds when Jog switch is pressed |
| Check gun trigger connection at wire feeder. Check gun trigger leads and trigger switch. See gun Owner’s | ||
but not when gun trigger is pressed. |
| Manual. | ||
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Wire does not feed with Jog button S2B |
| Check continuity of Jog button S3, and replace if necessary. | ||
pressed. |
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| Check motor control board PC1 and connections, and replace if necessary | |||
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Electrode wire feeding stops or feeds |
| Realign drive rolls. | ||
erratically during welding. |
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| Check hub assembly (see Parts List). | |||
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Wire feeds as soon as power is applied. |
| Check gun trigger. See gun Owner’s Manual. | ||
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Wire does not feed until trigger is |
| Check for short between gun trigger leads and weld cable. Repair or replace gun trigger leads. | ||
pressed but continues to feed after trig- |
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ger is released. |
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Gas valve rattles loudly and wire feeds |
| Check for short between gun trigger leads and weld cable. Repair or replace gun trigger leads. | ||
slowly or erratically. |
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Gas does not flow; wire feeds. |
| Check gas valve and flowmeter. | ||
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Wire feeds, but gas does not flow with |
| Check coil voltage and connections of gas valve GS1. Check continuity of coil. Replace GS1 if necessary. | ||
gun trigger pressed. |
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| Check continuity of Purge switch S2A, and replace if necessary. | |||
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Wire feeds, but gas does not flow with |
| Check continuity of Purge switch S2A, and replace if necessary. | ||
Purge switch S2 pressed. |
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| Check coil voltage and connections of gas valve GS1. Check continuity of coil. Replace GS1 if necessary. | |||
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Wire feeds and electrode wire is ener- |
| Check coil voltage and connections of gas valve GS1. Check continuity of coil. Replace GS1 if necessary. | ||
gized, but gas flow is irregular. |
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| Clear blockage in gas hose or replace hose. | |||
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| Clear blockage in gun. See gun Owner’s Manual. |
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Motor runs at full speed. |
| Check motor control board PC1 and connections, and replace if necessary. | ||
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| Check resistance and connections of active wire speed potentiometers and replace if necessary. |
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Wire drive motor coasts (no brake at trig- |
| Check motor control board PC1 and connections, and replace if necessary. | ||
ger release). |
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Meter does not work properly. |
| Check optional meter board PC2 and connections, and replace if necessary | ||
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