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Failure to keep the nozzle adequately cleaned can result in the
following problems:
A SHORTED nozzle results when spatter buildup bridges the
insulation in the nozzle allowing welding current to flow through
it as well as the contact tip. When shorted, a nozzle will steal
welding current from the wire whenever it contacts the grounded
work piece. This causes erratic welds and reduced penetration.
In addition, a shorted nozzle overheats the end of the gun,
which can DAMAGE the front-end of the gun.
A RESTRICTED nozzle is created when enough slag builds up
in the nozzle to affect the direction, concentration, and or rate of
the shielding gas flow. This problem can cause porous, brittle
welds and reduce penetration.
TESTING FOR A SHORTED NOZZLE
Arcing between the nozzle and the work piece ALWAYS means
the nozzle is shorted, but this can be hard to detect through the
lens of a welding helmet. The following testing method is
another way to tell if a nozzle is shorted.
With the welder unplugged from the ac power source, touch the
probes of an ohmmeter or continuity tester to the end of the
TROUBLE
Dirty, porous brittle weld
Wire feed works but no arc
Arc works but not feeding wire.
Nothing works except fan
Low output or non-penetrating weld.
Wire is birdnesting at the drive roller
Wire burns back to contact tip
Ground clamp and/or cable gets hot
Gun nozzle arcs to work surface
14
Table 3. Troubleshooting
POSSIBLE CAUSE
1. Plugged welding nozzle
2. No shielding gas
3. Wrong Type of Gas
4. Dirty or rusty welding wire
1. Bad ground or loose connection
2. Bad connection to gun or faulty gun
1. Faulty wire speed control assembly
2. No tension on the drive roller
3. Faulty drive motor (very rare)
1. Faulty trigger on gun
2. Faulty transformer (rare)
3. Exceeded duty cycle; thermal protector opened
1. Loose connection inside machine
2. Too long or improper extension cord
3. Wrong type or size wire
4. Poor ground connection
5. Wrong size contact tip
6. Loose gun connection or faulty gun assembly
7. Wrong welding polarity set
8. Dirty or rusty welding wire
1. Too much tension on drive roller
2. Gun liner worn or damaged
3. Contact tip is clogged or damaged
4. Liner is stretched or is too long
1. Gun liner is worn or damaged
2. Liner stretched or is too long
3. Wrong size contact tip
4. contact tip clogged or damaged
Bad connection from cable to clamp
Slag buildup inside nozzle or nozzle is shorted
contact tip and the outside of the nozzle. If there is any
continuity at all, the nozzle IS shorted. Clean or replace as
needed.
PREVENTIVE MAINTENANCE
Except for internal and external cleaning, cleaning the nozzle,
and occasionally retightening screws, there is no periodic
maintenance recommended for your welder.
TROUBLESHOOTING
The following TROUBLESHOOTING information is provided as
a guide to help resolve some of the more common problems
that could be encountered.
Table 3 is a troubleshooting table provided to help you
determine a possible remedy when you are having a problem
with your welder. This table does not provide all possible
solutions, only those possibilities considered to likely be
common faults. The table consists of a TROUBLE or symptom,
a POSSIBLE CAUSE for that symptom, and a POSSIBLE
REMEDY for that symptom.
1. Clean or replace nozzle
2. Tank empty, flow restricted, or regulator set too low
3. See SELECTING SHIELDING GAS in the WELDING
INSTRUCTION GUIDE for proper selection
4. Replace spool of wire
1. Check ground and connections tighten as necessary
2. Check connection to gun or replace gun
1. Replace wire speed control assembly
2. Adjust the drive tension
3. Replace drive motor
1. Replace trigger
2. Replace transformer
3. Allow welder to cool at least 10 minutes
(observe and maintain proper duty cycle
1. Blow inside of machine out with compressed air, clean
and tighten all connections
2. See EXTENSION CORD USE in this manual
3. Use correct size welding wire
4. Reposition clamp and check cable to clamp
connection
5. Use correct size contact tip
6. Tighten gun or replace gun
7. Change polarity to proper for wire being used
8. Replace spool of wire
1. Adjust the drive tension
(see INSTALLING THE WELDING WIRE)
2. Replace gun liner
3. Replace contact tip
4. Trim liner to proper length
1. Replace gun liner
2. Trim liner for proper length
3. Use correct size contact tip
4. Replace contact tip
Tighten connection or replace cable
Clean or replace nozzle as needed
POSSIBLE REMEDY
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