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Troubleshooting
Problem
No Weld Output
1. Unit not plugged into
2. Building's fuse or
3. Power Switch
Poor Welding Occurs
1. Electrode Tips deformed,
2. Tongs dirty or oxidized.
3. Poor contact with
4. Coatings on workpieces
5. Material too thick
Longer Than Normal
1. Electrode Tips deformed,
Weld Time Required
2. Metals to be
3. Tongs dirty or oxidized.
4. Facility line voltage low.
Burn Through
1. Weld time too long.
at Weld Point
2. Tongs out of alignment.
3. Electrode Tips deformed,
Electrode Tips
1. Not enough Tong
Overheating
2. Weld time too long.
3. Material too thick
Electrode Tips Arcing
1. Not enough Tong
on Workpieces
2. Electrode Tips
3. Workpiece material has
Hole in Weld
Contact area of Electrode
Tips too large.
Molten Material
1. Electrode Tips
Forced Out Around
the Weld Point
2. Weld time too long.
3. Too much Tong pressure.
Follow all safety precautions whenever diagnosing or servicing
the tool. Disconnect power supply before service.
Item 61205
Possible Causes
electrical outlet.
circuit breaker blown.
damaged or worn.
dirty, oxidized, or pitted.
workpieces.
inhibiting good contact.
for Spot Welder.
dirty, oxidized, or pitted.
welded are dirty.
dirty, oxidized, or pitted.
pressure.
for Spot Welder.
pressure.
misaligned.
become welded to Tips.
misaligned.
For technical questions, please call 1-888-866-5797.
Likely Solutions
1. Plug Power Cord into electrical outlet.
2. Replace building's fuse or reset circuit breaker.
3. Have a qualified technician inspect Power
Switch and replace if necessary.
1. Dress or replace Electrode Tips. Refer to
Dressing Electrode Tips on page 9 or
Replacing Electrode Tips on page 12.
2. Clean or replace Tongs.
3. Adjust Tong pressure. Refer to Adjusting Tong
and Operating Lever Pressure on page 10.
4. Remove paint, oxides, chemical compounds
including galvanized coating.
5. Ensure that workpiece thickness is within capacity of
Spot Welder. Refer to Specifications on page 7.
1. Dress or replace Electrode Tips. Refer to
Dressing Electrode Tips on page 9 or
Replacing Electrode Tips on page 12.
2. Clean metals with fine wet-dry sandpaper.
3. Clean or replace Tongs.
4. Check input line voltage with voltmeter.
1. Shorten weld time.
2. Realign Tongs. Refer to Tong and Electrode
Tip Alignment on page 9.
3. Dress or replace Electrode Tips. Refer to
Dressing Electrode Tips on page 9 or
Replacing Electrode Tips on page 12.
1. Increase Tong pressure. Refer to Adjusting Tong
and Operating Lever Pressure on page 10.
2. Shorten weld time.
3. Ensure that workpiece thickness is within capacity of
Spot Welder. Refer to Specifications on page 7.
1. Increase Tong pressure. Refer to Adjusting Tong
and Operating Lever Pressure on page 10.
2. Realign Tips or dress Tips to correct diameter. Refer
to Tong and Electrode Tip Alignment and/or Dressing
Electrode Tips on page 9.
3. Dress or replace Electrode Tips. Refer to Dressing
Electrode Tips on page 9 or Replacing Electrode
Tips on page 12.
Dress Electrode Tips to restore spot diameter and
face angle to approximate that of new tip. Refer
to Dressing Electrode Tips on page 9.
1. Dress Electrode Tips so they align correctly and lie flat
on the workpiece. Refer to Dressing Electrode Tips
and/or Tong and Electrode Tip Alignment on page 9.
2. Shorten weld time.
3. Decrease Tong pressure. Refer to Adjusting Tong
and Operating Lever Pressure on page 10.
Page 13
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