Bernard 195399 Operation Manual page 12

Part VI Troubleshooting Guide (cont.)
PROBLEM
7. Extreme spatter.
8. Porosity in weld.
9. Gun running hot.
10. Liner is discolored full length.
11. Sporadic feeding of aluminum electrode.
*In some cases with aluminum and mild steels, it may be necessary to use a contact tip with either a larger or smaller bore size.
POSSIBLE CAUSE
1. Improper machine parameters.
2. Improper contact tip installation.
3. Improper shielding.
4. Contaminated wire or work piece.
1. Insulator worn.
2. Gas diffuser damaged.
3. Extreme heat or duty cycle.
4. Solenoid faulty.
5. No gas.
6. Flow improperly set.
7. Gas ports plugged.
8. Ruptured gas hose.
9. Control circuit loss.
10. Worn, cut or missing o-rings.
11. Loose fittings.
1. Exceeding duty cycle.
2. Loose or poor power connection.
1. Short circuit to electrode.
2. Broken copper stranding in power cable.
1. Contact tip galling.
2. Synthetic liner melting.
3. Wire deformed by feed rolls.
CORRECTIVE ACTION
1. Adjust parameters.
2. Adjust nozzle/contact tip relationship.
3 a. Verify shielding gas coverage.
b. Verify gas mixture.
4. Clean wire and work piece.
1. Replace nozzle/insulator.
2. Replace gas diffuser.
3. Replace with heavy duty consumables.
4. Replace solenoid.
5 a. Install full tanks.
b. Check supply.
c. Hose leaks.
6. Adjust.
7 a. Clean or replace gas diffuser.
b. Clean nozzle.
8. Repair or replace cable or line.
9. See 'Electrode Does Not Feed'.
10. Replace o-rings
11. Tighten gun & cable connections to speci-
fied torque. See 'Maintenance & Repair'
(Section 7).
1. a. Replace with properly rated Bernard gun.
b. Decrease parameters to within gun rating.
2. a. Clean, tighten or replace cable grounding
connection.
b. Tighten gun & cable connections to
specified torque. See 'Maintenance & Repair'
(Section 7).
1. Isolate electrode reel from feeder and drive
block. Consult feeder manufacturers manual.
2. Replace MIG Gun.
1. Inspect & replace.*
2. a. Replace liner.
b. Replace with composite liner.
c. Replace with Q-Gun neck
and jump liner.
3. Adjust drive rolls as per feeder manufacturer's
manual.
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