Harbor Freight Tools Vulcan Migmax 215 Owner's Manual & Safety Instructions page 60

Troubleshooting
Be CERTAIN to shut off the Welder, disconnect it from power, and discharge the MIG Gun to
ground before adjusting, cleaning, or repairing the unit.
Problem
1. Insufficient wire feed pressure.
2. Incorrect wire feed roll size.
Wire feed motor
runs but wire does
3. Damaged MIG Gun, cable, or liner assembly.
not feed properly
4. Feed Tensioner is too tight.
1. Excess wire feed pressure.
2. Incorrect Contact Tip size.
Wire creates a bird's
3. MIG Gun Cable Connector not fully
nest during operation
inserted into Wire Feed mechanism.
4. Damaged liner.
1. Gun cable is severely bent and Wire
Feed mechanism cannot feed wire.
2. Gun liner is clogged or worn.
3. Gun liner is too small for welding
wire being used.
Wire stops
during welding
4. Wire is tangled on the spool.
5. Wire is not making contact with Feed Rollers.
6. Feed Roller is not making enough contact
with wire or is crushing flux-cored wire.
1. Wire not feeding properly.
2. Incorrect Contact Tip or liner
size or excessive wear.
3. Incorrect wire feed speed.
4. Loose MIG Gun cable or ground cable.
5. Damaged MIG Gun or loose
connection within Gun.
Welding arc
6. Incorrect polarity for process being run.
not stable
7. Gas coverage may be insufficient or too high.
8. Poor connection with workpiece.
1. Incorrect line voltage.
2. Improper gauge or length of cord.
Weak arc strength
3. Not enough current.
Follow all safety precautions whenever diagnosing or servicing the equipment.
Page 28
IMPORTANT!
Possible Causes
For technical questions, please call 1-888-380-0318.
Likely Solutions
1. Increase wire feed pressure properly.
Follow step 27 on page 14.
2. Flip roll to correct size. Follow the Wire Spool
Installation instructions on page 8.
3. Have a qualified technician inspect these
parts and replace as necessary.
4. Loosen Feed Tensioner so it applies only
enough pressure to prevent continued
spinning after the Gun Trigger is released.
1. Adjust wire feed pressure properly.
Follow step 27 on page 14.
2. Replace with the proper tip for wire used.
3. Insert Gun Cable Connector properly. Follow
steps 15 and 16 on page 12.
4. Have a qualified technician inspect and
repair/replace as necessary.
1. Straighten Gun cable.
2. Check gun liner for obstruction. Replace if necessary.
3. Check that gun liner is correct size for wire.
4. Check wire for cross winding or tangled spool.
5. Check Feed Rollers and ensure correct
groove for wire diameter is being used.
6. Check Feed Tensioner and ensure it is set properly.
1. See first Troubleshooting section above.
2. Replace with the proper tip or liner size for wire used.
3. Adjust wire feed speed to achieve a more stable arc.
4. Check to ensure that all connections are tight.
5. Have a qualified technician inspect and
repair/replace as necessary.
6. Ensure polarity is correct for operation:
DCEP for MIG welding and DCEN for
Flux-Cored self-shielded welding.
7. Ensure gas flow rate is set according to Settings Chart.
Make sure MIG Gun Cable Connector is fully inserted
into Wire Feed mechanism with no O-Rings exposed.
8. Check the ground clamp connection to
the workpiece and machine. Ensure
the MIG Gun is properly secured.
1. Check the line voltage and, if insufficient, have
a licensed electrician remedy the situation.
2. Do not use an extension cord on this Welder.
Use only one of the supplied power cords for
this Welder or an identical replacement cord.
3. Switch current to proper setting for metal thickness.
Item 63617