Troubleshooting - Bernard TG Series Owner's Manual

5.0 – TROUBLESHOOTING
PROBLEM
POOR WIRE FEED
SHORT TIP LIFE
GUN OVERHEATING
SWITCH MALFUNCTIONING
WELD POROSITY
POSSIBLE CAUSE

CONDUIT LINER CLOGGED OR KINKED

INCORRECT LINER SIZE OR CONTACT TIP

LINER CUT TOO SHORT AND NOT SEATING PROPERLY IN GAS
DIFFUSER

DRIVE ROLLS TOO TIGHT RESULTING IN SCORING OF WELDING
WIRE

WELDING WIRE DIRTY, RUSTY OR TOO MUCH CAST

DRIVE ROLLS TOO TIGHT RESULTING IN SCORING OF WELDING
WIRE

WELDING WIRE DIRTY, RUSTY OR TOO MUCH CAST

UNCOATED WIRE BEING USED, INCREASING USAGE

WRONG TIP SIZE

OVER TORCH RATED DUTY CYCLE

LOOSE CONSUMABLES

LOOSE RETAINING SCREW ON QUICK CONNECT BLOCK

INSUFFICIENT GAUGE POWER CABLE AND/OR GROUND CABLE

LOOSE CONNECTOR CONES AND/OR CONE NUTS

GUN BEING RUN BEYOND ITS AMPERAGE RANGE

ELECTRICAL MALFUNCTION IN POWER SOURCE

LOOSE CONSUMABLES

BAD CONNECTION OF LEADS TO SWITCH TERMINALS

SPATTER BUILD UP BETWEEN LEVER AND SWITCH HOUSING

CONTACTS DIRTY IN SWITCH

SWITCH HOUSING SCREWS LOOSE

BROKERN OR WORN SWITCH LEAD

SPATTER BUILD UP IN NOZZLE BLOCKING GAS

LEAKS IN GAS HOSE OR IMPROPER CONNECTION

O-RINGS ON POWER PIN ARE CUT OR DAMAGED

INNER TUBE LOOSE FROM CONNECTOR CONE

POOR WIRE FEED (SEE ABOVE)

IMPROPER SHIELDING GAS OR WELDING WIRE

RUSTY OR POOR QUALITY WELDING WIRE

PARENT METAL RUSTY OR CONTAMINATED OR HIGH IN
SULPHUR CONTENT

FLOW IMPROPERLY SET
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