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Table 3. Troubleshooting
TROUBLE
Dirty, porous brittle
weld
Wire feed works but
no arc
Arc works but not
feeding wire
Nothing works
except fan
POSSIBLE
CAUSE
.,,,,, ..............................
1. Plugged welding nozzle
2 No shielding gas
& 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
POSSIBLE
REMEDY
1. Clean or replace nozzle
2 Tank empty, flow restricted, or
regulator set too tow
3, See SELECTING SHIELDING
GAS in the WELDING
INSTRUCTION GUIDE for proper
selection
4., Replace spool of wire
I
Check ground and connections
tighten as necessary
2, Check connection to gun or
replace gun
I Replace wire speed control
assembly
2, Adjust the drive tension
3. Replace drive motor
I Replace trigger
2 Replace transformer
3 Allow welder to cool at least 10
minutes (observe and maintain
proper duty cycle
I, Blow inside of machine out with
Low output or
non-penetrating weld
machine
2 Too tong or improper
extension cord
3 Wrong type or size wire
4 Poor ground connection
5, Wrong size contact tip
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
Wire is birdnesting
at the drive roller
Wire burns back
to contact tip
Ground clamp andlor
cable gets hot
Gun nozzJe arcs
to work surface
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
i3 Contact tip is clogged or
Idamaged
4 Liner is stretched or is too
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
,€!arnp
Slag buildup inside nozzle or
nozzle is shorted
6 Tighten gun or replace gun
7 Change polarity to proper for
wire beil_j used
8. Replace spool of wire
1, Adjust the drive tension
(see INSTALLING THE WELDING
WIRE)
2 Replace gun liner
3 Replace conlact tip
4 Trim liner to proper length
t Replace gun liner
2 Trim liner for proper length
3 Use correct size contact tip
4 Replace contact tip
lighten connection or replace cable
Clean or replace nozzle as needed
21
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