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9-1 Troubleshooting Table
PROBLEM
1. Electrode does not feed.
2. Contact tip burn back.
3. Tip disengages from the
gas diffuser.
4. Short contact tip life.
5. Erratic arc.
6. Erratic wire feeding.
7. Extreme spatter.
SECTION 9 — TROUBLESHOOTING
POSSIBLE CAUSE
1. Feeder relay.
2. Broken control lead.
3. Poor adaptor connection.
4. Improper / worn drive roll.
5. Drive roll tension misadjusted.
6. Burn back to contact tip.
7. Wrong size liner.
8. Buildup inside of liner.
1. Improper voltage and/or wire feed
speed.
2. Erratic wire feeding.
3. Improper tip stickout.
4. Improper electrode stickout.
5. Faulty ground.
1. Worn gas diffuser/retaining head.
2. Improper tip installation.
3. Extreme heat or duty cycle.
1. Contact tip size
2. Electrode eroding contact tip.
3. Exceeding duty cycle.
1. Worn contact tip.
2. Buildup inside of liner.
3. Wrong tip size.
4. Not enough bend in neck.
1. Buildup inside of liner.
2. Wrong size liner.
3. Improper drive roll size.
4. Worn drive roll.
5. Improper guide tube relationship.
6. Improper wire guide diameter.
7. Gaps at liner junctions.
8. Feeder malfunction.
9. Worn contact tip.
1. Improper machine parameters.
2. Improper tip installation.
3. Improper shielding gas coverage.
4. Contaminated wire or workpiece.
CORRECTIVE ACTION
1. Consult feeder manufacturer.
2. a. Test and connect spare control lead.
b. Install new cable.
3. Test and replace leads and/or contact pins.
4. Replace drive roll.
5. Adjust tension at feeder.
6. See 'Contact tip burn back'.
7. Replace with correct size.
8. Replace liner or clean out with compressed air, check
condition of electrode.
1. Adjust parameters.
2. See 'Erratic wire feeding'.
3. Adjust nozzle / tip relationship.
4. Adjust wire stickout.
5. Replace cables and/or connections.
1. Replace tip and/or gas diffuser / retaining head.
2. Install as per section 6-1 Changing Consumables on page
15.
3. Replace with heavy duty consumables. See appropriate
Spec Sheet for details.
1. Replace with proper size.
2. Inspect and/or change drive rolls.
3. Replace with properly rated Bernard MIG Gun.
1. Replace contact tip.
2. Replace liner, check condition of electrode.
3. Replace with correct tip size.
4. Replace with 45° or 60° neck.
1. Replace liner, check condition of electrode.
2. Replace with new liner of proper size.
3. Replace with proper size drive roll.
4. a. Replace with new drive roll.
b. Repair worn drive roll.
5. a. Adjust / replace guide as close to drive rolls as
possible.
b. Eliminate all gaps in electrode path.
6. Replace with proper guide diameter.
7. a. Replace with new liner trimmed as per section 6-4
Changing the Liner on page 18.
b. Replace guide tube / liner trimming as close to mating
component as possible.
8. Consult feeder manufacturer.
9. Inspect and replace.*
1. Adjust parameters.
2. Adjust nozzle / tip relationship.
3. a. Verify shielding gas coverage.
b. Verify gas mixture.
4. Clean wire and workpiece.
TG008-1.0
24
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